Tracker Off-Road 800SX Service Manual
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Tracker Off-Road 800SX Service Manual

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SERVICE MANUAL
p/n: 2263-005
9/20
800SX

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Questions and answers

Eric and Rena Reiner
January 24, 2025

getting clicking noise when trying to start the engine

0
1 comments:
Mr. Anderson
February 10, 2025

A clicking noise when starting the engine of a Tracker Off-Road 800SX could be caused by a low voltage condition, an intermittent circuit issue, or a problem with the starter solenoid or wiring. Checking the battery voltage, ensuring proper connections, and inspecting the starter system components may help identify and resolve the issue.

This answer is automatically generated

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Michael Cors
June 21, 2025

Is there a proper procedure to adjust the gear linkage? We seem to have problems with the 800sx jumping out of gear when in high

0
Mike
May 18, 2025

Rear axle removal, 2020 tracker 800 sx

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Summary of Contents for Tracker Off-Road 800SX

  • Page 1 SERVICE MANUAL p/n: 2263-005 9/20 800SX...

  • Page 3: Table Of Contents

    Table of Contents General Information/Foreword ........2 Engine ................60 Specifications ............... 2 Removing Engine ............60 Torque Specifications ........... 3 Cylinder Head and Related Components....65 Torque Conversions (ft-lb/N-m)........4 Removing Cylinder Head and Related Components...65 Gasoline — Oil — Lubricant ......... 4 Servicing Left-Side Components.........84 Preparation for Storage ..........

  • Page 4: General Information/Foreword

    NOTE: Specifications subject to change without notice.  This Service Manual contains service, maintenance, and MISCELLANEOUS troubleshooting information for the 2021 800SX model. Tire Size (Front) 26 x 9 R14 The complete manual is designed to aid service personnel 26 x 10 R14 27 x 9 R14 in service-oriented applications.

  • Page 5: Torque Specifications

    Torque Part Part Bolted to ft-lb N-m Torque Specifications STEERING COMPONENTS (cont.) Bracket Rack Mount Frame (with weld nut) 61.2 Bracket Rack Mount Frame (with nut) 21.8 NOTE: Torque specifications have the following tol-  Intermediate Shaft Rack & Pinion 61.2 erances: Steering Shaft...

  • Page 6: Torque Conversions (Ft-Lb/N-M)

    Torque Part Part Bolted to ft-lb N-m Torque Conversions DRIVE TRAIN COMPONENTS (ft-lb/N-m) Top Differential Mount Frame 16 21.8 Frame Lower Differential Mount 16 21.8 Differential Top Differential Mount 45 61.2 Differential Bottom Differential Mount 45 61.2 ft-lb ft-lb ft-lb ft-lb Drain Plug Front Differential...

  • Page 7: Preparation For Storage

    When using ethanol-blended gasoline, it is not necessary to add a gasoline antifreeze since ethanol will prevent the Preparation for Storage accumulation of moisture in the fuel system. CAUTION The manufacturer recommends the following procedure Do not use white gas. Only approved gasoline additives to prepare the vehicle for storage.

  • Page 8: Preparation After Storage

    6. Charge the battery; then install. Connect the battery cables making sure to connect the positive cable Preparation after Storage first. CAUTION Taking this vehicle out of storage and correctly preparing Before installing the battery, make sure the ignition it will ensure many hours of trouble-free riding. The manufacturer recommends the following procedure: switch is in the OFF position.

  • Page 9: Periodic Maintenance/Tune-Up

    3. Install the snorkel to the air inlet and tighten the clamp securely. Reinstall the left-side access panel. Periodic Maintenance/ Tune-Up Engine Air Filter Tighten all nuts, bolts, and cap screws. Care must be Primary Air Filter/Safety Filter/Clean- taken that all calibrated nuts, bolts, and cap screws are out Valve tightened to specifications.
  • Page 10 MOD086 MOD084A MOD087 MOD084B 5. Inspect the primary air filter element for damage or 4. Loosen the clamp indicated and disconnect the snor- dirt. If damaged the filter must be replaced. kel from the housing; then clean and inspect the inside of the snorkel;...
  • Page 11 MOD089 MOD092 7. Remove and inspect the safety filter. 2. Install the air filter housing cover with the clean-out valve at the 5 o’clock position; then turn the air filter housing cover clockwise until it seats. NOTE: The clean-out valve should be near the ...

  • Page 12: Valve Clearance

    MF039A MOD597 5. Install the right access panel and secure with two 1/4-turn fasteners. CAUTION A torn air filter can cause damage to the engine. Dirt and dust may get inside the engine if the element is torn. Carefully examine the element for tears before and after cleaning it.

  • Page 13: Spark Plug

    Spark Plug A light brown insulator indicates that the plug and fuel/ air ratio are correct. A white or dark insulator indicates that the engine may need to be serviced. To maintain a hot, strong spark, keep the plug free of carbon. MOD095A 2.

  • Page 14: Front Differential Lubricant - Transaxle Fluid

    10. Inspect the area around the drain plug and oil filter for leaks. 11. Install the maintenance cover. 12. Check to make sure the oil fill cap is secure and the oil level stick is installed correctly; then lower the cargo box to its locked down position.

  • Page 15: Driveshaft/Coupling

    Headlight — Taillight/Brake Light Light Bulb Replacement CAUTION Use only specified bulbs indicated in the Specifications chart as replacement bulbs. NOTE: The bulb portion of the headlight is fragile.  HANDLE WITH CARE. When replacing the head- MOD126A light bulb, do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing.
  • Page 16 MOD097A MOD114A 3. Install the rubber boot making sure it is sealed around the bulb and connect the wire harness. MOD115A 2. Remove screw (A); then flex the cargo box fender away from the cargo box to access and remove screw (B).
  • Page 17 3. Remove the taillight/brake light assembly and dis- connect it from the harness by pushing on the con- nector lock. MOD117A MOD110 MOD113 6. Position the outer cargo box side panel behind the two tabs on the cargo box fender; then fit all tabs into their adjoining slots in the side panel.

  • Page 18: Shift Cable

    8. Start at the rear of the cargo box and tuck the outer side panel under the cargo box floor and work it into place from back to front. MOD38 NOTE: There should be an average operating load  on the vehicle when adjusting the headlight aim. MOD111 2.

  • Page 19: Hydraulic Brake System

    NOTE: If the distance on each side of the upper tilt  steering wheel adjuster bracket and the shifter hous- ing is the same and the vehicle does not properly engage Park or Low, shift cable replacement may be required. 3.
  • Page 20 B. Slowly depress the brake pedal several times. 3. Carefully check the entire hydraulic brake system to ensure all hose connections are tight, the bleed C. Install one end of a clear hose onto the RIGHT screws are tight, the protective caps are installed, and REAR bleeder screw and direct the other end no leakage is present.

  • Page 21: Burnishing Brake Pads

    6. Burnish the brake pads. BRAKE DISC Using a micrometer, measure the thickness of the brake disc in the contact surface. If thickness is 0.125 in. (3 mm) or less, the disc must be replaced. To replace the brake disc, see Drive System – Hub/Brake Disc. Burnishing Brake Pads Brake pads must be burnished to achieve full braking MOD301...
  • Page 22 6. Remove the belt by pulling it over the driven clutch and rotating the driven clutch. MOD205A 4. Remove the six clamps securing the clutch cover; then remove clutch cover. MOD215 NOTE: Firmly grasp clamps as they can completely  CHECKING detach from clutch cover assembly and spring away.
  • Page 23 7. Install the clutch cover making sure the gasket is 3. Continue to push in and rotate the driven clutch completely in the grove on the engine side. Install six counterclockwise while continually tightening the clamps securing the clutch cover cap screw.

  • Page 24: Steering/Body/Controls

    Steering/Body/Controls The following steering components should be inspected periodically to ensure safe and proper operation: A. Steering wheel secure. B. Steering has equal and complete full-left and full-right turning capability. C. Steering sector mounting bolts tight. MOD220 D. Ball joints not worn, cracked, or damaged. E.
  • Page 25 3. Remove the input shaft cap screw and lock nut of the EPS; then remove the output shaft cap screw and lock nut of the EPS. Discard lock nuts. Inspect cap screws and replace if damaged. MOD274 MOD270A MOD273 INSTALLING STEERING SHAFT/EPS ASSEMBLY ...
  • Page 26 4. Reinstall the input shaft cap screw and new lock nut to the EPS; then reinstall the output shaft cap screw and new lock nut of the EPS. Tighten both to 24 ft-lb (32.6 N-m). MOD173 2. Reinstall the two cap screws on the occupant side and the one cap screw in the front left inner fender securing the EPS.
  • Page 27 MOD173 MOD317 1. Using a suitable lift and stands lift the vehicle until 4. Remove the four cap screws and lock nuts securing the front wheels are off the ground; then remove the the rack and pinion bracket to the frame. Discard front wheels.
  • Page 28 INSPECTING RACK AND PINION 1. Inspect the tie rod ends for damaged threads, torn boots, or excessive wear. 2. Inspect the tie rods for bends or deformation. 3. Inspect the rack and pinion-to-tie rod boots for tears or deterioration. MOD320 MOD322 4.
  • Page 29 4. Install the wheels and using a crisscross pattern, 4. Using a wrench, loosen the lock nut (B) while hold- tighten the wheel nuts in 20 ft-lb (27.2 N-m) incre- ing the tie rod at the location indicated (C); then ments to a final torque of 100 ft-lb (136 N-m);...
  • Page 30 3. Place the outer tie rod ends into the knuckles and secure with the castle nuts (B) (coated with red Loc- tite #271). Tighten to 32 ft-lb (43.5 N-m); then install new cotter pins (A) and spread the cotter pins. NOTE: If the slots in the castle nut (B) are not ...

  • Page 31: Steering Knuckles

    MOD322A MOD325 3. Reinstall the rack and pinion into the vehicle; then 7. With the cap screws completely removed tap the ball i nstall the wheels and using a crisscross pattern, joint end out of the knuckle; then remove the tighten the wheel nuts in 20 ft-lb (27.2 N-m) incre- knuckle.
  • Page 32 2. Insert the CV shaft into the knuckle; then install the knuckle to the upper and lower ball joints and secure with the two cap screws and two new lock nuts. Tighten to 45 ft-lb (61.2 N-m). MOD330 7. Install the retaining plate. ...

  • Page 33: Accelerator Pedal

    9. Install the wheels and using a crisscross pattern, tighten the wheel nuts in 20 ft-lb (27.2 N-m) incre- ments to a final torque of 100 ft-lb (136 N-m). 10. Remove the vehicle from the support stand. Accelerator Pedal REMOVING Disconnect the connector from the accelerator pedal;...
  • Page 34 MOD306 MOD308 5. Remove the snap ring on the steering column; then remove the washer (A) and thrust washer (B); then slide the shift lever off of the steering housing. MOD307 2. Install the adjuster bracket to the bottom of the steer- ing housing;...

  • Page 35: Shift Cable

    MOD220 MOD309 Shift Cable REMOVING NOTE: The shift cable can be accessed from the top  by removing the floor or from the bottom by remov- ing the skid plate. Removing from the bottom in most cases will be easier. 1.
  • Page 36 XX382 MOD297A INSTALLING 1. Route the cable into position making sure there are no kinks or sharp bends. 2. Guide the shift cable into the shift cable bracket. Install the cable end to the shift arm stud and secure with a new E-clip. Secure the adjuster nut to the bracket.

  • Page 37: Lcd Gauge

    LCD Gauge REMOVING/INSTALLING To remove the gauge, pull out on one side of it; then dis- connect the multi-pin connector and remove the gauge. PR087A MOD244A To install the gauge, connect the multi-pin connector and press the gauge into the dash. NOTE: Ensure the rubber mounting ring is ori- ...

  • Page 38: Hood

    MOD044A MOD196 CAUTION Upper Hood Always use a wrench to hold the tie rod ends when loosening or tightening the jam nuts or damage to the boots could occur. REMOVING 2. Turn the left-side and right-side tie rods (C) in equal 1.
  • Page 39 MOD252 MOD133A 2. There are four cap screws per side that secure the bottom of the front fascia. Front Fascia/Grille 3. Remove the three T20 cap screws securing the outer front of the fascia; then remove them from the oppo- site side.
  • Page 40 MOD140A MOD138A MOD136 MOD135A 5. Install the upper grille and tighten the two T30 cap INSTALLING screws; then install the hood and secure the 1/4-turn 1. Place the front fascia into position and secure the two locks. T30 shouldered cap screws. MOD044C MOD140A 2.
  • Page 41 Lower Fascia REMOVING 1. Remove the two cap screws located below the front tow hooks. MOD511 2. Position the tow hooks into place; then install the two cap screws behind each tow hook. Tighten to 20 ft-lb (27.2 N-m). MOD509 2.

  • Page 42: Front Fenders/Fender Flares

    Front Fenders/Fender Flares Removing the fender is recommended to remove the fender flare REMOVING 1. Remove the hood, upper hood and mid/upper dash- board. Located in the front of the inner fender, remove the two cap screws securing the fender, fender flare and grille to the headlight bracket.
  • Page 43 MOD607 MODC065A 7. With the fender removed from the vehicle, remove the four cap screws on the inside of the fender; then remove the fender flare from fender taking note of the four tabs on the fender flare. MODC065 2. Place the fender into position; then install the two cap screws on the top portion of the fender.
  • Page 44 MOD592 MOD262 4. Install the four cap screws in the inner fender. 7. Located in the front of the inner fender, install the two cap screws securing the fender, fender flare and grille to the headlight bracket. Install the upper hood, mid/upper dashboard and hood;...
  • Page 45 MOD191 MOD190 3. Remove the four cap screws securing the door hinge 2. Reinstall the three cap screws from inside the and remove the door hinge; then remove the remain- behind-the-seat storage box panel. ing cap screws securing the side panel; then remove the side panel.

  • Page 46: Doors

    2. Remove the cap screws and lock nuts at the front of the roof. Account for the washers and the lock nuts. Doors Remove the roof. Discard lock nuts. Inspect cap screws and replace if damaged. ADJUSTING DOORS 1. Door adjustment is accomplished by loosening the striker plate cap screws;...

  • Page 47: Rear Bumper (Optional)

    Rear Bumper (Optional) REMOVING/INSTALLING 1. Remove the four cap screws and lock nuts; then remove bumper. Discard lock nuts. Inspect cap screws and replace if damaged. MOD686 MOD684 2. Remove the four cap screws and two lock nuts per bumper bracket; then remove bumper brackets. Dis- card lock nuts.
  • Page 48 MOD592 MOD290 3. Remove the six fasteners on the occupant side secur- 6. Remove the seven cap screws securing the floor to ing the splash panel to floor. frame. MOD287 MOD291 MOD288 MOD292 4. Remove the two cap screws located near the front 7.
  • Page 49 MOD291 MOD287 MOD292 MOD288 2. Install the one cap screw located near the rearmost 5. Install the three fasteners securing the splash panel corner of the floor on each side. on each side MOD290 MOD592 3. Install the two cap screws located near the front tires 6.

  • Page 50: Dashboard (Mid/Upper)

    Dashboard (Mid/Upper) REMOVING 1. Disconnect the battery; then remove the cap screws indicated, taking note of the different fastener types in the different locations. MODC061 4. From behind the dashboard, disconnect the LCD gauge (A), and DC power outlets (B)(C). Note the orientation of the connectors for installing purposes;...

  • Page 51: Dashboard (Lower)

    Dashboard (Lower) REMOVING 1. Remove the mid/upper dashboard; then remove the three cap screws on each fender. MODC061A 3. Install the cap screws indicated, taking note of the different fastener types in the different locations; then connect the battery. MOD592 CAUTION When removing the lower steering adjuster mount, the steering wheel tilt assembly will be unsecured and...
  • Page 52 3. Remove the key switch locking nut by turning coun- terclockwise; then push the key switch through hole to clear the lower dashboard; then disconnect the electrical connectors on the left side of the dash- board. MOD267 INSTALLING 1. Position the lower dashboard into place taking note of the tabs on each side of the lower dashboard.

  • Page 53: Splash Panel

    MOD266A MOD592 Splash Panel REMOVING 1. Remove the mid/upper dashboard, lower dashboard, side panels, seats, seat base, EPS, lower steering adjuster cap screw, and floor. 2. Disconnect the master brake cylinder, throttle cable, and shift cable. 3. Remove the five cap screws along the top of the splash panel;...

  • Page 54: Skid Plates

    MOD311 MOD231 2. Lift the muffler assembly upward to clear the three holders underneath the muffler assembly. MOD312 2. Connect the master brake cylinder, throttle cable, and shift cable MOD232 3. Install the floor, lower steering adjuster cap screw, INSPECTING EPS, seat base, seats, side panels, lower dashboard, 1.
  • Page 55 MOD224 MOD222 5. Remove the two cap screws and nuts on the hinge CAUTION points. When the lift support is detached from cargo box, the box can drop with force. Take care when operating the box without lift support. 2. Remove the nut securing the upper lift support bolt; then with the cargo box secured in place, remove the bolt.

  • Page 56: Seats

    DISASSEMBLING 1. Remove the six cap screws securing the passenger Seats seat backrest to the passenger seat backrest frame; then remove the passenger seat backrest from the passenger seat backrest frame. REMOVING/INSTALLING PASSENGER SEAT BOTTOM 1. To remove the passenger seat bottom, raise the front of the seat and unhook both of the “C”...
  • Page 57 MOD609 MOD227 INSTALLING 2. Lift the seat adjustment lever; then move the seat assembly toward the front of the vehicle to clear the 1. Install the seat backrest by hooking both of the tubes rear mounting channel. of the seat backrest (A) into the “C” channels (B). Fold up;...

  • Page 58: Behind-The-Seat Storage Box Panel

    MOD524 MOD228A 2. Install the six cap screws underneath the driver seat ASSEMBLING rails. Tighten to 2 ft-lb (2.7 N-m). 1. Position the seat bottom to the seat assembly; then install the four cap screws securing the seat bottom to the seat assembly. Tighten to 2 ft-lb (2.7 N-m). MOD227 Behind-the-Seat Storage MOD523...
  • Page 59 7. Remove the six cap screws securing the behind-the- seat storage box panel; then remove the eight cap screws securing the behind-the-seat storage box panel to the floor; then remove the behind-the-seat storage box panel.  NOTE: When removing the behind-the-seat storage box panel, it might be necessary to gently pull down on the top of the panel to clear the metal channel that connects the left and right rear ROPS.

  • Page 60: Seat Base

    MOD282 MOD593 4. Reinstall the passenger seat back hinge; then reinstall 7. Reinstall the seats; then both side panels; then both rear the 11 cap screws securing the passenger seat back inner fenders. hinge. Seat Base REMOVING 1. Remove the seats; then remove the rear inner fenders and side panels;...

  • Page 61: Troubleshooting

    Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Steering shaft binding 2. Lubricate/replace steering shaft 3. Tire inflation pressure incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 62: Engine

    Engine This section has been organized into sub-sections which show a progression for the complete servicing of the engine.  NOTE: Photographs are used for clarification pur- poses only and may not depict exact situation. To service the crankshaft, the engine must be removed from the frame.
  • Page 63 5. Remove the flywheel cover; then remove the PTO stub shaft; then remove the crank position sensor from the crank position sensor bracket. MOD391 3. Near the engine PTO, remove the retaining ring securing the inner clutch cover to the engine; then near the transaxle input shaft remove the four cap MOD539 screws securing the inner clutch cover to the tran-...
  • Page 64 MOD546 MOD563A 7. Remove the two cap screws securing the engine to the transaxle. Account for the spacers and washers between the engine and transaxle. MOD544 MOD543 MOD544A 9. Remove the air intake to the engine. MOD554 8. Remove the two cap screws securing the starter to the engine backplate;...
  • Page 65 MOD548 MOD551 11. Remove the two cap screws and nuts securing the exhaust to the exhaust manifold; then gently pull the exhaust from the exhaust manifold. MOD552 NOTE: Coolant will come out when removing the  coolant hoses. It is recommended to have a drain pan or suitable absorbant material near when removing MOD549.
  • Page 66 16. Remove the wires going to the alternator; then remove the temperature/manifold absolute pressure (TMAP) sensor connector from the temperature/ manifold absolute pressure (TMAP) sensor. MOD553 MOD558 MOD555 15. Remove the coolant sensor connector from the cool- ant sensor; then disconnect the coil connectors from the coils;...

  • Page 67: Cylinder Head And Related Components

    MOD560 MF031 18. Gently remove the engine from the chassis, being careful of any electrical components, hoses, straps, and etc. Cylinder Head and Related Components  NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components.
  • Page 68 INSTALLING VALVE COVER REMOVING AND INSTALLING CAMSHAFT DRIVE BELT 1. Thoroughly clean all gasket and sealing material from the valve cover and cylinder head; then using a 1. Disconnect the negative battery cable; then loosen new gasket and seals, apply a small amount of high the alternator mounting bolt (A) and adjusting cap temperature silicone sealant between the arrows on screw (B) and remove serpentine drive belt.
  • Page 69 MF161A MF093A 4. Loosen the cap screw securing the camshaft drive 6. Inspect belt tensioner for excessive wear, binding, or adjuster pulley; then remove the timing belt and rough bearing feel. Replace as necessary. replace if damaged in any way. MF094A MF161A 7.
  • Page 70 MF088A MF161A 9. Install a new timing belt keeping the timing marks 13. Install the water pump pulley and tighten to 7.7 ft-lb aligned; then push tensioner arm in the direction of (10 N-m); then install the crankshaft drive pulley; the arrow until the gap between the tensioner and then tighten the crankshaft bolt to specifications.
  • Page 71 MOD590 MOD590 5. Account for the water pump O-ring. 3. Install the water pump pulley. Tighten to 5.9 ft-lb (8 N-m). MOD591 MOD589 Servicing 4. Install the timing belt cover (see Removing Cylinder Head and Related Components in this section); then NOTE: The water pump is only serviceable as an ...
  • Page 72 ADJUSTING VALVE CLEARANCE Shims Part Number Thickness 3040-157 2.06 mm 3040-158 2.08 mm 3040-159 2.10 mm 3040-160 2.12 mm 3040-161 2.14 mm 3040-162 2.16 mm 3040-163 2.18 mm 3040-164 2.20 mm 3040-165 2.22 mm MF078B 3040-166 2.24 mm Available Valve Clearance Adjustment Shims 3040-167 2.26 mm 3040-168...
  • Page 73 3. Firmly holding the bucket retainer and rotate the crankshaft so as to position the camshaft lobe high point away from the valve bucket; then, using a small screwdriver and magnet, tip the valve adjust- ment shim up and out of the valve bucket. MF076B 3.
  • Page 74 MF074 MF092 6. Remove the Valve Adjust Tool; then rotate the crank- shaft through at least two revolutions, making sure the shim is adequately seated in the valve bucket. 7. Recheck the valve clearance on adjusted valves as prescribed in (see CHECKING VALVE CLEAR- ANCE in this section).
  • Page 75 MF075A MF125A 6. Inspect shim for its size; then calculate which shim needs to be installed (see Calculating Shim to Install in this section). 7. Replace the removed shim(s) with the proper thick- ness shim as calculated; then tighten the camshaft bearing cap screws to specifications using the sequence shown making sure that camshaft gear tim- ing marks are correctly aligned.
  • Page 76 13. Install the water pump drive pulley (C) and crank- shaft drive pulley (D) and tighten the water pump pulley cap screws and crankshaft drive pulley bolt to specifications. MF087B MF081A 14. Install the serpentine belt and tighten as required. MF088B 11.
  • Page 77 MF111A MF098A 4. Install a 5 mm x 80 cap screw in the hole next to the pinned hole on the intake camshaft drive gear and tighten to secure the master and slave gears in posi- tion; then rotate the camshafts to relieve the valve spring pressure (approximately 1/3 turn).
  • Page 78 NOTE: It is recommended to loosely install the cam-  shaft bearing caps in their original positions to pre- vent mixing up while performing other related operations. MF101A 11. Inspect the camshaft drive gears for excessive wear, chipped or missing teeth, and security to the cam- shafts.
  • Page 79 MF126A MF125A 15. Install the camshaft bearing caps in their proper loca- CAUTION tion and orientation: then secure with the cap screws tightened to specifications in the sequence shown. Failure to remove the 5 mm cap screw prior to turning the engine will result in damage to the cylinder head.
  • Page 80 MF087B MF133A 6. Remove the cap screws securing the exhaust pipe to the exhaust manifold and separate the exhaust pipe from the manifold. Account for the gasket. MF088B 19. Using a new valve cover gasket, install the valve cover and tighten to specifications. 20.
  • Page 81 11. Remove the camshaft drive belt (see REMOVING AND INSTALLING CAMSHAFT DRIVE BELT in this section). 12. Remove camshafts (see REMOVING AND INSTALLING CAMSHAFTS in this section). 13. Remove the eight head bolts securing the cylinder head to the cylinder block in the sequence shown. Account for the hardened washers on each head bolt.
  • Page 82 3. Use a suitable valve spring compressor, compress the valve spring (A); then depress the sleeve (B) to release the collets (C). MF029A MF164A 4. Remove the collets (C) from the valve stem; then release the spring compressor and account for valve spring (A), sleeve (B), valve spring retainer (D), valve stem seal (E), valve spring seat washer (F), and valve (G).
  • Page 83 9. Wash all parts in cleaning solvent to remove lapping compound and dry with compressed air. 10. Note the position of the lap ring on the face of the valve. The lap ring (H) should be at or very near the center of the valve face (I).
  • Page 84 MF159A MF167A 2. If intake and exhaust manifolds were removed, using NOTE: Collets can be held in position during  new gaskets, install and secure with attaching nuts assembly by applying a small amount of grease to the (seven intake and six exhaust) and tighten to specifi- inner surface of the collets.
  • Page 85 1st pass to 30 N-m (22 ft-lb) 2nd pass to 50 N-m (37 ft-lb) 3rd pass to 70 N-m (51 ft-lb) MF135A 9. Install the air inlet tube to the throttle body and tighten the clamp securely; then insert the throttle control connector (6) into the receptacle in the throt- tle body and seat securely.

  • Page 86: Servicing Left-Side Components

    14. Fill the cooling system with the appropriate quantity and mixture of coolant and install the coolant cap; then bleed the cooling system 15. Install the driver- and passenger-side rear inner fend- ers. Servicing Left-Side Components  NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be MOD602 addressed and to service only those components.
  • Page 87 6. Remove the belt by pulling it over the driven clutch and rotating the driven clutch. MOD205A 4. Remove the six clamps securing the clutch cover; then remove clutch cover. MOD215 7. With the driven clutch still on the transaxle input NOTE: Firmly grasp clamps as they can completely ...
  • Page 88 DRIVE CLUTCH 1. Using parts-cleaning solvent, wash grease, dirt, and foreign matter off all components; dry with com- Disassembling pressed air. NOTE: Note the timing marks (X) on the cover, spi-  2. Remove any drive belt dust accumulation from the der, and movable sheave.
  • Page 89 MOD458 MOD460 3. Align the match marks (X) and install the clutch 3. Remove the spider and driven spring from the driven cover and secure with six cap screws. Tighten using clutch assembly. a crisscross pattern to 110 in-lb (12.4 N-m). MOD461 WC653A 4.
  • Page 90 5. Inspect the bushing in the movable sheave and sta- tionary sheave for wear, damage, or cracks. 6. Inspect the spring for cracking or twisting. 7. Inspect the cam for grooves. 8. Check the bearings for smoothness and play. Assembling 1.
  • Page 91 6. Using a suitable compressor, put a light amount of pressure compressing the driven clutch; then install the four cap screws securing the cam to the driven clutch. In a crisscross pattern, tighten to 47 in-lb (5.3 N-m). MOD465 4. Install the spring into the clutch assembly with the spring tab in the clutch groove.
  • Page 92 MOD217 MOD219 9. Install the clutch cover making sure the gasket is 5. Continue to push in and rotate the driven clutch completely in the grove on the engine side. Install six counterclockwise while continually tightening the clamps securing the clutch cover cap screw.
  • Page 93 3. Remove the cap screws securing the flywheel cover; then remove the flywheel cover; then remove the two cap screws securing the crankshaft position sensor bracket; then remove the crankshaft position sensor from the crankshaft position sensor bracket. MOD209 FLYWHEEL ...
  • Page 94 2. Install the crankshaft position sensor to the crank- shaft position sensor bracket and tighten the cap screw to 8 ft-lb (10.9 N-m); then spray a light film of alcohol on the crankshaft position sensor wire; then install the flywheel cover while routing the crank- shaft position sensor wire correctly and gently pull on the crankshaft position sensor wire to take the slack out from under the flywheel cover.

  • Page 95: Engine Block And Components

    MOD393 MF237A 4. Install the drive clutch, drive belt, driven clutch and 4. Apply a thin line of high temperature silicone sealant clutch cover. around the sealing surface of the oil pan as illus- trated; then place the oil pan into position on the engine block and secure with the cap screws and tighten evenly to specifications.
  • Page 96 INSTALLING OIL PUMP 1. Align the flats on the inner rotor bore with the flats on the crankshaft; then using a new gasket and ser- viceable weatherstrip seals, install the oil pump assembly onto the crankshaft and secure to the engine block with the cap screws.

  • Page 97: Installing Engine

    FI595A MOD544A 4. Install the oil pan (see REMOVING AND 3. Install the two cap screws with blue Loctite #243 INSTALLING OIL PAN in this section). securing the backplate to the front mount and tighten to 51.7 ft-lb (70 N-m); then position the starter into 5.
  • Page 98 MOD550 MOD548 5. Located on the PTO side, install the two cap screws 8. Install the air intake to the engine and tighten clamp. with blue Loctite #243 with the spacers between the engine and transaxle. Tighten to 75 ft-lb (102 N-m). MOD545A 9.
  • Page 99 10. Install the crank position sensor into the crankshaft position sensor bracket and tighten to 8 ft-lb (10.9 N-m). Install the PTO stub shaft and tighten cap screws to 36.9 ft-lb (50 N-m). Install the flywheel cover and tighten cap screws securely. MOD561 MOD541A MOD560...
  • Page 100 13. Install the coolant sensor connector to the coolant sensor; then connect the coil connectors to the coils; then install the engine oil pressure switch connector to the engine oil pressure switch that is located near the engine oil filter; then attach the engine ground located above the engine oil pressure switch.

  • Page 101: Troubleshooting

    MOD392 MOD393 18. Install the drive clutch, drive belt, driven clutch and clutch cover; then install the rear inner fenders and cargo box. 19. Fill with coolant (see the Liquid Cooling System sec- tion) and bleed the cooling system; then connect the battery connections.
  • Page 102 Problem: Engine idles poorly Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve seating poor 2. Replace — service seats — valves 3. Valve guides defective 3. Replace guides 4. Fuel injector obstructed 4. Replace fuel injector Problem: Engine runs poorly at high speed Condition Remedy...

  • Page 103: Fuel/Lubrication/Cooling

    Fuel/Lubrication/ Cooling NOTE: Some photographs and illustrations used in  this section are used for clarity purposes only and are not designed to depict actual conditions. TROUBLESHOOTING 1. Verify that the electric fuel pump is operating by lis- tening for a “whirring” sound for several seconds MOD567 after the key switch is turned to the ON position.

  • Page 104: Oil Filter/Oil Pump

    6. Inspect the gas tank mountings for security, signs of cracking, or wearing through the tank. Fuel Pump 7. Inspect all gas and vent hoses for cracks, softening, or deterioration. Replace as required. NOTE: The fuel pump is only serviceable as an ...

  • Page 105: Liquid Cooling System

    Liquid Cooling System NOTE: Use a good quality, biodegradable glycol-  based, automotive-type antifreeze. When filling the cooling system, use a 60/40 coolant/water mixture or one which will satisfy the coldest anticipated weather conditions of the area in accordance with the coolant manufacturer’s recommendations.
  • Page 106 MODC054 MOD475 2. Gently lift up on the front fenders where it meets the 4. Remove the two cap screws and lock nuts securing grille to gain access to the upper headlight cap screw; the radiator bracket to the frame; then remove the then remove the upper headlight cap screw;...
  • Page 107 Installing 1. Place the radiator into position, making sure the grommets are correctly installed; then install the radiator bracket into the vehicle; then secure the radi- ator bracket with the two cap screws and new lock nuts; then tighten to 20 ft-lb (27.2 N-m); then con- nect the radiator fan electrical connection.
  • Page 108 THERMOSTAT Removing 1. Drain some coolant from the cooling system. 2. Remove the coolant hose from the thermostat hous- MOD586 Inspecting 1. Inspect the thermostat for corrosion, wear, or spring damage. 2. Using the following procedure, inspect the thermo- stat for proper operation. A.
  • Page 109 MOD587 MOD474 2. Install the two cap screws securing the thermostat 2. Remove the four cap screws securing the fan to the housing and tighten to 15 ft-lb (20 N-m). radiator fan bracket; then remove the fan from the radiator. MOD551C 3.

  • Page 110: Troubleshooting

    WATER PUMP NOTE: The water pump is only serviceable as an  assembly (see Engine section — Removing Cylinder Head and Related Components). MOD474 Troubleshooting Problem: Starting impaired Condition Remedy 1. Gas contaminated 1. Drain gas tank and fill with clean gas Problem: Idling or low speed impaired Condition Remedy...

  • Page 111: Electrical System

    Electrical System The electrical connections should be checked periodi- cally for proper function. TESTING ELECTRICAL COMPONENTS All electrical tests should be made using the Dealer Diag- nostic Service (computer connected), gauge diagnostic menu (a menu in the LCD gauge) or the Fluke Model 77 Multimeter.
  • Page 112 NOTE: If no active codes are present on the LCD or NOTE: If any codes are active and verified with the   verified through the Dealer Diagnostic Service and Dealer Diagnostic Service, EPS replacement is not the vehicle is experiencing steering-related issues, always necessary.

  • Page 113: Ignition Switch

    Code Fault Description Fault Condition Possible Cause EPS Fault Recovery Method C1372 Battery Voltage Low EPS power low-voltage condition System voltage is low (less than 11 VDC at EPS will auto-recover when the has been detected. the EPS). Wire harness issue, faulty battery supply returns to normal.

  • Page 114: Accessory Receptacle/Connector

    Secondary Coils Accessory Receptacle/ CAUTION Connector Disconnect the injector connectors before performing the following procedure. 1. Connect the primary ignition coil connector. Remove  NOTE: This test procedure is for either the recepta- the spark plug cap from the spark plug. cles or the connectors.
  • Page 115 MOD483 MOD612 3. Buckle the driver’s seat belt. On the switch side of 3. Disconnect the switch connector from the switch and the connector, connect one meter lead to one pin and remove any nylon straps securing the switch. the other meter lead to the opposite connector pin. Installing 1.
  • Page 116 DRIVE SELECT Resistance Component data can be retrieved using the Dealer Diag- nostic System. Utilize the Sensor Data screen. 1. Remove the switch assembly from the dash; then dis- connect the harness from the switch. NOTE: The switch can be removed from the dash ...

  • Page 117: Fan Motor

    2. Select the DC Volts position on the tester and NOTE: The HI/LO bulb-connector uses a three-pin  observe the meter readings for each switch positions. connector with the corresponding color codes: white, yellow/black, and black. 2WD/4WD Switch 1. Behind the headlight remove the connector from the WIRE COLOR headlight;...

  • Page 118: Power Distribution Module (Pdm)

    NOTE: If battery voltage is not shown and the head-  lights are illuminated, inspect the Lights fuse. If bat- tery voltage is shown on the meter, replace the bulb. BRAKE LIGHT Voltage  NOTE: Perform this test at the socket end of the taillight-brake light harness (pigtail).

  • Page 119: Efi Sensors/Components

    5. The meter must show battery voltage from one side NOTE: The throttle body will not go through the  of the connector terminal ends. full verification process if the temperature is below 32° F (0° C). NOTE: Battery voltage will be indicated from only ...
  • Page 120 3. Reading is typically 14.7 ohms. NOTE: If resistance is not present or largely out of specification, replace the injector. CRANKSHAFT POSITION (CKP) SENSOR Resistance 1. Disconnect the crankshaft position sensor. Set the meter selector to the OHMS position. 2. Connect the red tester lead to one of the terminals indicated on the sensor side;...
  • Page 121 ENGINE COOLANT TEMPERATURE (ECT) SENSOR Component data can be retrieved using the Dealer Diag- nostic Service. Utilize the Sensor Data screen.  NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see Gauge Diagnostic Menu in this section). 1.
  • Page 122 2. Remove the sensor from the sensor housing account- ing for an O-ring. 3. Install the new speed sensor into the housing with a new O-ring lightly coated with multi-purpose grease; then secure the sensor with the cap screw (threads coated with blue Loctite #242).
  • Page 123 MOD295B ATV2116 NOTE: If readings are erratic, clean the resistor  wiper and resistor with clean alcohol and retest. If still not correct, replace the fuel pump assembly. Replacing Fuel Level Sensor To replace the fuel level sensor, use the following proce- dure: 1.
  • Page 124 MOD482 MOD490 5. Connect the blue wires using the supplied splice con- nectors from the fuel level sensor kit. Secure the wires. Installing Fuel Pump Assembly 1. Place the fuel pump assembly into the fuel tank with a new gasket aligning the match marks; then secure with the fuel tank nut.

  • Page 125: Winch

    3. Connect the red tester lead to the blue/brown wire (B) and the black tester lead to the pink/black wire (A); then turn the ignition switch ON and observe the meter. The meter should read 0.4-1.4 DC volts. MOD693A MOD490A 4.

  • Page 126: Starter Motor

    INSTALLING 1. Position the dowel pins onto the starter; then install Starter Motor the starter. Secure with two cap screws. Tighten to 14.8 ft-lb (20 N-m). NOTE: The starter motor is only serviceable as an  assembly. REMOVING 1. Disconnect the battery; then remove the clutch cover, drive clutch, driven clutch, drive belt, and inner clutch cover, and flywheel cover.

  • Page 127: Starter Relay

    NOTE: If a “click” is heard and more than 1 volt is  indicated by the multimeter, replace the starter relay. If no “click” is heard and the multimeter continues to indicate battery voltage, proceed to step 4. 4. Disconnect the two-wire plug from the starter relay; then connect the red tester lead to the green wire and the black tester lead to the orange wire.

  • Page 128: Alternator/Regulator

    NOTE: If a “click” is heard and more than 1 volt is NOTE: If voltage rises above 15.5 DC volts, the reg-   indicated by the multimeter, replace the start relay. If ulator is faulty or a battery connection is loose or cor- no “click”...

  • Page 129: Electronic Control Module (Ecm)

    3. Holding tension on the belt, tighten the adjuster cap screw (A) securely; then remove the pry and tighten the pivot bolt (B) securely. MOD234 1. Turn the ignition switch ON. 2. Depress and hold both left and right buttons together for approximately three seconds until “DIAGNOS- MOD439 TIC”...
  • Page 130 Air Pressure (AIR PRESS) 2. Battery voltage with engine idling (charging = 13.8 VDC or greater). 3. Battery voltage with electrical accessories operating, engine idling (13.5 VDC or greater). 4. Battery voltage starter cranking (10.5-11.5 VDC). Coolant (COOLANT) MOD576 Display: Air pressure as measured by the Temperature Manifold Absolute Pressure (TMAP) sensor DTC: P0068, P0107, P0108 Usage: Monitor air pressure to verify the following:...
  • Page 131 Fuel Sensor (FUEL) DTC: P2122, P2123, P2127, P2128, P2138 Usage: Monitor accelerator position sensor percentage to verify the following: 1. Accelerator position sensor signal. Brake Switches (BRAKE) MOD238 Display: Fuel level signal from the fuel level sensor. DTC: C1400 Usage: Check output of the fuel level sensor:* 1.

  • Page 132: Diagnostic Trouble Codes (Dtc)

    Code List Diagnostic Trouble NOTE: Each of the following numerical codes will  have a one-letter prefix of C, P, or U. A “C” prefix Codes (DTC) denotes a chassis malfunction, a “P” prefix denotes a power train malfunction, and a “U” prefix denotes a loss of communication with the gauge.
  • Page 133 Display Fault Description Possible Cause Fault Recovery Method P0202 Cylinder #2 Fuel Injector Circuit Open Injector #2 has been disconnected or its interconnect harness is Correct condition** open. P0203 Cylinder #3 Fuel Injector Circuit Open Injector #3 has been disconnected or its interconnect harness is Correct condition** open.
  • Page 134 Display Fault Description Possible Cause Fault Recovery Method P0643 Sensor Reference Voltage #1 Circuit High 5-volt sensor power circuit #1 has been shorted to battery power. Correct condition* P0651 Sensor Reference Voltage #2 Circuit 5-volt sensor power circuit #2 has been shorted to chassis ground. Correct condition* Low/Open P0653 Sensor Reference Voltage #2 Circuit High 5-volt sensor power circuit #1 has been shorted to battery power.
  • Page 135 Display Fault Description Possible Cause Fault Recovery Method U0100 Lost Communication with ECM The ECM CAN circuit or its interconnect harness is intermittent or Correct condition* has failed. U0155 LCD Gauge to ECM CAN Communication The LCD gauge CAN circuit or its interconnect harness is Correct condition* intermittent or has failed.

  • Page 136: Wiring Diagram

    Wiring Diagram GRN/ORG (3) ORG/GRY (2) ORG/RED GRN/ORG ORG/RED RED/BRN YEL/ORG BLK/RED RED/WHT WHT/RED RED/WHT WHT/BRN ORG/BLK YEL/BLK ORG/BLK TAN/VLT ORG/GRY (1) +12V IGNITION (2) GROUND RED/BRN (3) +12V MEMORY TAN/GRN PLUG (4) YEL/BLK (5) HIGH BEAM YEL/GRY (6) FUEL GAUGE LBL/VLT WHT/GRY (7) CAN HIGH (+) GRY/YEL (8) CAN LOW (-)

  • Page 137: Troubleshooting

    Troubleshooting Problem: Battery does not charge Condition Remedy 1. Battery wires/connections shorted — loose — open 1. Repair — replace — tighten battery wires/connections 2. Serpentine belt loose — bad 2. Tighten — replace belt 3. Alternator/regulator failed 3. Replace alternator assembly Problem: Charging unstable Condition Remedy...

  • Page 138: Drive System

    2. Using a Torx wrench, remove the mounting cap screw from the driveshaft side of the actuator. Drive System GENERAL INFORMATION The front differential is a 3.0:1 ratio. The die-cast aluminum housings have been assembled with thread-rolling screws (trilobular). When assembling with these screws, start the screws carefully into the housing;...

  • Page 139: Front Differential

    INSTALLING 6. Turn the ignition switch to the ON position and check the operation by shifting the drive select 1. Lubricate the O-rings on the actuator; then ensure all switch several times. mounting surfaces are clean and free of debris. 2.
  • Page 140 MOD502 MOD325 9. Remove the upper differential mounting cap screw 5. Pull the steering knuckle away from the axle. and lock nut. Discard lock nut. Inspect cap screw and replace if damaged. MOD349 6. Support the axle to prevent it from dropping or hang- ing;...
  • Page 141 Disassembling Input Shaft 1. Remove the front differential; then remove the actua- tor on the front differential; then using a Torx wrench, remove the cap screws securing the pinion housing and actuator bracket; then remove the actua- tor bracket (A). MOD347 12.
  • Page 142 XR348 XR350 3. Remove the snap rings from the input shaft; then remove the input shaft from the pinion housing. XR351 Assembling Input Shaft GC009A 1. Place the pinion housing in a press and install the 4. Using a seal removal tool, remove the input shaft input shaft bearing.
  • Page 143 GC014 XR354 3. Lubricate the input shaft with High-Performance #2 5. Place the dowel pin into the differential housing; Molybdenum Disulfide Grease packing the splines; then install a new gasket. Place the coupler onto the then assemble allowing excess grease to freely shift fork;...
  • Page 144 MOD355 MOD360 NOTE: If the cover is difficult to remove, pry on the  Disassembling Differential Assembly cover in more than one recessed location. 1. Using a Torx wrench, remove the cap screws secur- ing the pinion housing; then remove pinion housing. 4.
  • Page 145 XR359 CC883 3. Secure the pinion gear in a bearing puller; then 2. Place the pinion assembly in a bearing puller; then remove the pinion bearing using a press. Account for install the bearing using a press. a collar and a bearing. CC884 3.
  • Page 146 Backlash NOTE: Always set backlash prior to any other  shimming. 1. Install the existing shim or a 0.051-0.055-in. shim on the gear case side of the ring gear assembly. GC040 GC031A 2. Install the ring gear with shim in the gear case; then while holding the pinion stationary, rock the ring gear forward and back to determine if any backlash exists.
  • Page 147 GC035 GC036B 2. Zero the dial indicator; then push the ring gear NOTE: The spider and ring gear assembly must be  toward the dial indicator and release. End-play replaced as a complete unit. should be 0.004-0.008 in. 3. Apply a liberal coat of grease to the O-ring; then 3.
  • Page 148 6. Install the shift fork assembly making sure the fork leg is facing upward. Apply a small amount of oil to the gasket; then install the gasket. GC060 CAUTION Make sure the tool is free of nicks or sharp edges or XR353 damage to the seal may occur.
  • Page 149 4. Install the upper differential mounting cap screw with a new lock nut. Tighten to 45 ft-lb (61.2 N-m); then tighten the lower differential mounting cap screws to 16 ft-lb (21.8 N-m). MOD348A 2. Install the lower differential mounting cap screws. Do not tighten at this time.

  • Page 150: Drive Axles

    Drive Axles REMOVING REAR DRIVE AXLE 1. Remove the hubs (see Hub/Brake Disc in this sec- tion). 2. Remove the cap screw and lock nut securing the knuckle to the upper A-arm. Discard lock nut. Inspect cap screw and replace if damaged. MOD350 6.
  • Page 151 1. Using CV Boot Clamp Tool, remove and retain both clamps for assembly purposes. MOD350 MOD514 2. Use a suitable form of protection on the outside sur- face of the CV joint, such as a strip of rubber or duct tape;...
  • Page 152 NOTE: The boot is positioned correctly when the  small end of the boot seats down into the recessed groove. 2. Using the boot clamp tool, secure the small clamp of the inner boot. MOD518 NOTE: Steps 1-5 can be used to replace the out- ...

  • Page 153: Driveshaft

    INSTALLING FRONT DRIVE AXLE 1. Verify the location of the O-rings (C) for the axles; then install the front axles by pushing the axle shaft (A) toward the inner CV joint housing (B) to release the “plunge” coupler; then while the axle shaft and the inner CV joint housing are pushed together install the axle to the differential;...

  • Page 154: Transaxle

    ASSEMBLY 1. Tilt the front of the driveshaft up and slide forward into the front differential space until it clears the rear cross member support. 2. Lightly coat the splines of the driveshaft with grease; then couple the driveshaft to the transaxle by gently sliding the driveshaft toward the rear of the vehi- cle.
  • Page 155 TA110 TA130 Front Output Seal Pinion Plug NOTE: The transaxle must be removed for this pro- NOTE: The transaxle does not need to be removed   cedure. for this procedure. 1. Using an awl and a mallet, pry the seal from the case 1.
  • Page 156 REMOVING TRANSAXLE 1. Remove the cargo box; then remove both rear inner fenders; then remove both rear drive axles; then remove the two cap screws underneath the front dif- ferential.  NOTE: Removal of front axles is not required. MOD544B 4.
  • Page 157 MOD544 MOD376 6. Remove the two cap screws securing the transaxle to the engine. Account for the spacers. MOD544A MOD563 MOD565 8. Uncouple the driveshaft from the transaxle by gently sliding the front differential with the driveshaft toward the front of the vehicle. Account for the MOD554 7.
  • Page 158 9. Remove the rear transaxle mount to frame cap screws and lock nuts (A); then gently slide the tran- saxle toward the front of the vehicle and remove the rear transaxle to transaxle mount cap screws and lock nuts (B); then being careful not to damage any items, gently remove the transaxle.
  • Page 159 TA131A MOD383 4. Lift on the shift rail assembly to disengage the rail NOTE: Use a suitable bearing seal protection tool  assembly from the case and rotate the rail away from when driving the bearing and gears into the lower the shift drum;...
  • Page 160 TA025A TA073A 8. Pry the pinion gear assembly to remove it from the CAUTION case. Account for the shim. When tapping the output shaft, make sure not to drop the shaft when it releases from the bearing to avoid gear damage.
  • Page 161 TA016 TA041 2. Inspect the gear teeth for nicks, cracks, chips, or 2. Inspect the rail for nicks, cracks, chips, or signs of signs of wear. If any are present, the gear must be wear. If any are present, the rail must be replaced. replaced.
  • Page 162 TA038A TA057A 2. Inspect the cam groove for signs of wear. If present, 5. Install the spring into the shift drum. replace the cam. TA121 6. Rotate the cam clockwise so the tab of the spring TA133A 3. Check the shaft splines for nicks, cracks, chips, or installs into the shift drum groove.
  • Page 163 8. Install the snap ring. G. Reverse Shaft 1. Inspect the bearings for free and smooth turning. If either bearing does not turn freely, it must be replaced. TA050 TA048 TA051 3. Inspect the shaft gear teeth for nicks, cracks, chips, or signs of wear.
  • Page 164 3. Inspect the shaft gear teeth for nicks, cracks, chips, or signs of wear. If any are present, the shaft must be replaced. TA054 H. Input Shaft 1. Inspect the bearings for free and smooth turning. If either bearing does not turn freely, it must be TA045 replaced.
  • Page 165 3. With the aid of an assistant and using an appropriate driver, remove the gear. TA132 7. Install the large outer snap ring with the shim. TA031 4. Remove the large outer snap ring and account for the shim. TA086 8.
  • Page 166 TA073 TA096 NOTE: To determine the appropriate shim, start  with the thickest shim and install the snap ring. If the snap ring will not fit in the groove, remove the shim and install the next size smaller shim. Continue until the snap ring can be installed.
  • Page 167 TA102 TA056 8. If backlash measurement is more than specified, 2. With the aid of an assistant and with the gear forks in remove the existing shim and install a thinner shim. position, install the input shaft and reverse shaft with chain as an assembly.
  • Page 168 TA062 TA065A 4. Pinch the forks together and slide the rail into posi- 7. Install the shift drum gear onto the shift drum align- tion in the case. ing the appropriate splines of the drum with the gear. 8. Install the shift shaft gear onto the shift shaft with the timing marks facing up;...
  • Page 169 12. Secure the cover with the cap screws and tighten to 20 ft-lb (27.2 N-m). 13. Install the detent (gold plug) with spring and O-ring. Tighten to 20 ft-lb. (27.2 N-m). MOD384A 11. Apply a coat of Loctite #5699 to the case; then ensuring the shift shaft (O-ring lightly coated with grease) and shift rail are correctly seated;...
  • Page 170 TA012C MOD381 3. Lightly coat the splines of the driveshaft with grease; 16. Using an appropriate seal installer, gently install a new then couple the driveshaft to the transaxle by gently plug over the pinion gear assembly so it fully seats past sliding the front differential with the driveshaft the chamfer —...
  • Page 171 MOD554 MOD544A 5. Install the two cap screws with blue Loctite #243 securing the backplate to the front mount and tighten to 51.7 ft-lb (70 N-m); then position the starter into place and install the two cap screws securing the starter to engine backplate;...

  • Page 172: Hub/Brake Disc

    MOD374 MOD345 8. Connect the shift cable to the transaxle. Then remove 11. Install the two cap screws underneath the front dif- the suitable strap that was putting a slight upward ferential; then tighten to 16 ft-lb (21.8 N-m); then tension on the engine.
  • Page 173 3. Using a socket and ratchet handle, tighten the nut until the stud is fully drawn into the hub. MOD331 3. Remove the hub nut securing the hub. 4. Remove the brake caliper(s). MOD351 NOTE: It is not necessary to remove the brake hoses INSTALLING ...

  • Page 174: Hydraulic Brake Caliper

    REMOVING 1. Secure the vehicle on a support stand to elevate the wheel; then remove the wheel. ! WARNING Make sure the vehicle is solidly supported on the sup- port stand to avoid injury. ! WARNING Never let brake fluid contact the eyes. Damage to the eyes will occur.
  • Page 175 NOTE: If brake pads are to be returned to service,  CLEANING AND INSPECTING do not allow brake fluid to contaminate them. 1. Clean all caliper components (except the brake pads) with DOT 4 brake fluid. Do not wipe dry. 2.
  • Page 176 6. Fill the reservoir; then bleed the brake system (see Periodic Maintenance/Tune-Up — Hydraulic Brake System). ! WARNING Never use brake fluid from an open container or reuse brake fluid. Moisture-contaminated brake fluid could cause vapor build-up (expansion) during hard braking resulting in greatly increased stopping distance or loss of control leading to injury or death.
  • Page 177 4. Remove the master cylinder. Discard the three crush washers. CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the vehicle. Inspecting 1. Inspect the master cylinder push rod and clevis for wear, bending, or elongation of clevis holes. 2.

  • Page 178: Troubleshooting Drive System

    Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Drive belt worn — broken 1. Replace drive belt 2. Vehicle shift lever in Park or Neutral 2. Shift vehicle to desired gear Problem: Power not transmitted from engine to either front wheel Condition Remedy 1.

  • Page 179: Suspension

    Suspension The following suspension system components should be inspected periodically to ensure proper operation: A. Shock absorber rods bent, pitted, or damaged. B. Rubber damper cracked, broken, or missing. C. Shock absorber body damaged, punctured, or leaking. MOD186 D. Shock absorber eyelets broken, bent, or cracked. NOTE: Before attempting to adjust suspension, ...
  • Page 180 FRONT MOD334 MOD180 REAR MODC070 MOD181 REMOVING SPRING REMOVING SHOCK 1. Remove the shock; then use a suitable spring compres- 1. Secure the vehicle on a support stand to elevate the sor, compress the spring and remove the retainer ring. wheels and to release load on the suspension.

  • Page 181: Front A-Arms

    Front A-Arms REMOVING 1. Remove the hubs (see Drive and Brake Systems sec- tion). 2. Remove the brake hose clamps from the upper A-arm; then cut the cable tie from the A-arm. Note the location of the white marks on the brake line for installation purposes.
  • Page 182 2. Install the A-arm assemblies into the frame mounts and secure with the cap screws. Only finger-tighten at this time. MOD336 8. Remove the snap ring from the ball joint; then remove the ball joint from the A-arm. MOD336 MOD337 MOD335 CLEANING AND INSPECTING 3.
  • Page 183 MOD130 MOD130A 7. Install the tie rod end and secure with the nut (coated 10. Install the wheels and using a crisscross pattern, with red Loctite #271). Tighten to 32 ft-lb (43.5 N-m); tighten the wheel nuts in 20 ft-lb (27.2 N-m) incre- then install a new cotter pin and spread the pin to ments to a final torque of 100 ft-lb (136 N-m).

  • Page 184: Rear A-Arms

    3. Remove the two cap screws per side securing the sway bar to the frame; then remove sway bar from frame. MOD504 MOD505 INSTALLING 1. Position the sway bar into the vehicle; then push the sway bar mount toward the center of the vehicle and lightly coat with grease on the sway bar where the sway bar mount will be;...
  • Page 185 MOD371 MOD372 CLEANING AND INSPECTING 1. Clean all A-arm components in parts-cleaning sol- vent. 2. Inspect the A-arm for bends, cracks, and worn bush- ings. 3. Inspect the frame mounts for signs of damage, wear, or weldment damage. INSTALLING 1. Install the A-arm assemblies into the frame mounts and secure with the cap screws and new lock nuts.

  • Page 186: Rear Knuckles

    2. Slide the knuckle onto the drive axle and into posi- tion on the A-arms; then secure the knuckle to the A-arms with cap screws and new lock nuts. Tighten to 45 ft-lb (61.2 N-m). 3. Tighten the hardware securing the A-arms to the frame mounts (from step 1) to 45 ft-lb (61.2 N-m).

  • Page 187: Wheels And Tires

    2. Remove the nuts securing the wheels; then remove the wheels. Wheels and Tires CLEANING AND INSPECTING 1. Clean the wheels and hubs with parts-cleaning sol- TIRE SIZE vent. ! WARNING 2. Clean the tires with soap and water. Use only approved tires when replacing tires. Failure to 3.

  • Page 188: Troubleshooting

    Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring preload incorrect 1. Adjust preload 2. Spring(s) weak 2. Replace spring(s) 3. Shock absorber damaged 3. Replace shock absorber 4. Shock absorbers too soft 4. Check/replace shock absorbers Problem: Suspension too stiff Condition Remedy 1.
  • Page 189 NOTES...
  • Page 190 NOTES...

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