Tracker Off-Road 500S Service Manual
  1. Manuals
  2. Brands
  3. Tracker Off-Road Manuals
  4. Offroad Vehicle
  5. 500S
  6. Service manual

Tracker Off-Road 500S Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

SERVICE MANUAL
p/n: 2262-399
9/20
500S

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 500S and is the answer not in the manual?

Questions and answers

Related Manuals for Tracker Off-Road 500S

Summary of Contents for Tracker Off-Road 500S

  • Page 1 SERVICE MANUAL p/n: 2262-399 9/20 500S...

  • Page 3: Table Of Contents

    Table of Contents General Information/Foreword ........2 Engine/Transmission ............ 40 Specifications ............... 2 Troubleshooting............41 Torque Specifications ........... 3 Removing Engine/Transmission........43 Torque Conversions (ft-lb/N-m)........4 Servicing Engine ............47 Gasoline — Oil — Lubricant ......... 4 Installing Engine/Transmission........86 Preparation for Storage ..........5 Fuel/Lubrication/Cooling..........

  • Page 4: General Information/Foreword

    CHASSIS This Service Manual contains service, maintenance, and Dry Weight (approx) 496.7 kg (1095 lb) troubleshooting information for the 2021 500S model. ROPS Tested Curb Weight 997.9 kg (2200 lb) The complete manual is designed to aid service personnel Length (overall) 270.3 cm (106.4 in.)

  • Page 5: Torque Specifications

    CYLINDER, PISTON, AND RINGS Piston Skirt/Cylinder Clearance 0.60-0.73 mm Torque Specifications Piston Diameter 15 mm from Skirt End 88.96-88.98 mm Piston Ring Free End Gap (max) (1st) 8.0 mm (2nd) 8.3 mm NOTE: Torque specifications have the following tol-  Bore x Stroke 89.0 x 71.2 mm erances:...

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

    Torque Part Part Bolted to Torque Conversions ft-lb SUSPENSION COMPONENTS (Front) (ft-lb/N-m) A-Arm Frame Knuckle Ball Joint Shock Absorber Frame/Upper A-Arm 32.5 ft-lb ft-lb ft-lb ft-lb SUSPENSION COMPONENTS (Rear) 35.4 69.4 103.4 A-Arm Frame 36.7 70.7 104.7 Shock Absorber Lower A-Arm/Frame 43.5 38.1 72.1...

  • 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 to Do not use white gas. Only approved gasoline additives 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

    Periodic Maintenance/ Tune-Up Tighten all nuts, bolts, and cap screws. Care must be taken that all calibrated nuts, bolts, and cap screws are tightened to specifications. It is advisable to lubricate certain components periodi- cally to ensure free movement. Apply light oil to the components using the following list as reference: PK096A A.

  • Page 10: Valve/Tappet Clearance

    14. Inspect the drain cap beneath the main housing for debris and for proper sealing. From under the vehicle check the drain located on the bottom of the intake tube. PK321 4. Slide out the air filter screen, then separate the inner and outer air filter elements to thoroughly clean.

  • Page 11: Testing Engine Compression

    ADJUSTING A. Place the Valve Clearance Adjuster onto the jam nut securing the tappet adjuster screw; then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw. B. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut;...

  • Page 12: Spark Plug

    5. While holding the throttle in the full-open position, crank the engine over with the electric starter until the gauge stops climbing (five to 10 compression strokes). PSI Hot (WOT) PSI Cold (WOT) 125-145 100-140 6. If compression is abnormally low, inspect the following items: A.

  • Page 13: Front Differential - Rear Drive Lubricant

    1. Park the vehicle on level ground. 9. Remove the oil level stick; the oil level must be within the operating range but not exceeding the 2. Remove the drain plug from the bottom of the engine upper mark. and drain the oil into a drain pan; then remove the seat.

  • Page 14: Driveshaft/Coupling

    To change the lubricant, use the following procedure: 1. Rotate the back of the headlight bulb counterclock- wise; then disconnect the wiring harness and discard 1. Place the vehicle on level ground. the bulb. 2. Remove each fill plug; then inspect the seal (replace if necessary).

  • Page 15: Shift Cable

    NOTE: There should be an average operating load  on the vehicle when adjusting the headlight aim. 2. Measure the distance from the floor to the midpoint of each headlight. 3. Using the measurements obtained in step 2, make horizontal marks on the aiming surface. 4.

  • Page 16: Hydraulic Brake System

    PK099 PK102 If either park or low range cannot be reached, the shift 5. Place the bushing and cable end onto the shift arm cable must be adjusted. stud; then install the washer and a new E-clip. Tighten the nuts (A) and (B) to 8 ft-lb (10.9 N-m). ADJUSTING SHIFT CABLE 6.
  • Page 17 CHECKING/REPLACING PADS C. Install one end of a clear hose onto the REAR bleeder screw and direct the other end into a The clearance between the brake pads and brake discs is container; then while holding slight pressure on adjusted automatically as the brake pads wear. The only the brake pedal, open the bleeder screw and maintenance that is required is replacement of the brake watch for air bubbles.

  • Page 18: Burnishing Brake Pads

    PK106 PK050A 3. Install the wheels and using a crisscross pattern, 2. Remove the battery by disconnecting the negative tighten the wheel nuts in 20 ft-lb (27.2 N-m) incre- cable first then the positive cable. Move the starter ments to a final torque of 45 ft-lb (61.2 N-m) (steel relay and cables up out of the way.
  • Page 19 CD966A PK109A 7. Install a fully threaded 6 x1 mm cap screw into the 5. Note the routing of the throttle cable and position of driven pulley fixed face; then turn the cap screw the clamps securing it. Remove the cap screws secur- clockwise to spread the pulley faces.
  • Page 20 2. Pinch the V-belt together near its center and slide the NOTE: At this point, the 6 mm cap screw used to  spacer and movable drive face onto the front shaft. separate the sheaves of the Driven Clutch can be Secure the drive face with a new nut.

  • Page 21: 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. PK112 D. Ball joints not worn, cracked, or damaged. 2.
  • Page 22 PK114A PK117A 3. Remove the steering shaft lift support cap screw and 6. Note the matching alignment marks on the pinion nut. Account for the two spacers. shaft and rack/pinion housing for assembly purposes. PK115 PK118A 4. Remove the two nuts securing the cap screws at the 7.
  • Page 23 9. With the marks still aligned from step 8, on the oppo- site side of the column, match mark the upper inter- mediate shaft joint to the bottom of the steering column housing. Remove the cap screw securing the joint to the upper steering shaft; then remove the intermediate steering shaft.
  • Page 24 INSPECTING RACK AND PINION 6. With the spacers in place, secure the lift support to the steering column using the cap screw and nut. 1. Inspect the tie rod ends for damaged threads, torn Tighten securely. boots, or excessive wear. 2.

  • Page 25: Steering Knuckles

    PR780 PR528A 4. Using an appropriate crowfoot and backing wrench, 5. Install the boot onto the rack and secure with the remove the tie rod assembly. nylon tie. NOTE: Tie rods come as a complete assembly. No 6. Center the rack in the steering rack assembly and ...
  • Page 26 PK123A PK126 7. Tap the ball joint end out of the knuckle; then remove the knuckle. 8. Using a suitable seal puller, remove both seals from the knuckle. Note the two different seals. PK125 2. Grease the bearing and seals; then using a suitable sized seal driver, install both inner and outer seals.

  • Page 27: Accelerator Pedal

    9. Secure the brake line to the knuckle; then secure the brake caliper to the knuckle with the two new “patch-lock” cap screws. Tighten to 20 ft-lb. PK127 6. Install the hub assembly onto the splines of the shaft. PK106 10.

  • Page 28: Shift Lever

    Shift Lever REMOVING NOTE: The dash must be removed prior to replace-  ment of the shift lever (see Dashboard). 1. Remove the E-clip (A) and washer (B) connecting the shift cable to the shift lever. Account for the bushing (C). PK133 3.
  • Page 29 PK132 PK102 3. From under the front body panel, measure the  NOTE: If the cable is being replaced, connect the installed length of the threads; then loosen the cable new cable to the end of the existing cable and pull the adjuster nuts.

  • Page 30: 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 1. Center the steering wheel; then using an open-end wrench to hold the tie rod ends (A), loosen the right- side and left-side jam nuts (B).
  • Page 31 PK136A PK140A 4. Disconnect both headlight assemblies; then remove the cap screws securing the bumper to the frame from both sides of the vehicle. Remove the bumper. PK137A 2. Remove the two cap screws at the front of the upper fascia secured to the frame;...

  • Page 32: Hood/Front Storage Compartment

    PK140A PK136A 4. Check and adjust headlight aim (see Headlight — Taillight/ Brake Light — Reverse Light section). Hood/Front Storage Compartment To access the front storage compartment, lift up firmly on the front of the hood to remove. To install, align the tabs of the hood into the front panel slots and press down firmly to secure.

  • Page 33: Floor

    PK069 PK143 INSTALLING 1. Install the front body panel; then secure it to the top of the dashboard using the plastic rivets. Place the PDM and diagnostic plug into position; then using the two cap screws, secure the panel to the frame. PK089 3.
  • Page 34 PK145A PK148A 3. Remove the accelerator pedal (see Accelerator Pedal in this section). 4. Remove the cotter pin and clevis pin securing the master cylinder plunger to the brake pedal lever. Remove the E-clip (A) securing the brake pedal lever to the bracket.

  • Page 35: Dashboard

    INSTALLING 1. Place the front of the floor into position in the vehi- cle first; then lower the rear and push down into posi- tion. 2. Secure the floor with the cap screws. 3. Install the accelerator and brake pedals using new E- clips.
  • Page 36 INSTALLING 1. To aid in installation of the dashboard, remove the bottom of the lift support from the steering column via the cap screw and nut. Account for the bushing. Tilt the lift support out; then install the dashboard into position. PK148A 7.

  • Page 37: Belly Panel

    Belly Panel REMOVING 1. Remove the body screws securing the belly panel to the underside of the frame. 2. Remove the belly panel. INSTALLING 1. Place the belly panel into position on the underside of the frame. PK148A 2. Install the body screws. Tighten securely. 5.

  • Page 38: Cargo Box

    CLEANING AND INSPECTING 1. Clean all cargo box components with soap and water. Cargo Box 2. Inspect the cargo box for cracks, tears, and loose hardware. REMOVING 3. Inspect the welds of the cargo box frame for cracking 1. Disconnect both taillight/brake light connectors. Pull or bending.

  • Page 39: Taillight Assembly

    PK324 PK325 3. Remove the two cap screws securing both left and right pivot panels to the tailgate. Unlatch the tailgate from the cargo bed; then with the aid of an assistant, tilt the tailgate down and lift up to remove. PK324 3.

  • Page 40: Seat

    INSPECTING 1. Inspect wiring harness, three-prong connector, lens, base, cap screws, and socket for damage. 2. Inspect all wires for corroding, pinching, and cracking. 3. Inspect the bulb for wattage, voltage, and proper operation. INSTALLING 1. Place the rear fender onto the cargo box and secure with the six plastic screws.

  • Page 41: 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 Problem: Steering oscillation Condition Remedy...

  • Page 42: Engine/Transmission

    SPECIAL TOOLS A number of special tools must be available to the techni- Engine/Transmission cian when performing service procedures in this section. Refer to the current Special Tools Catalog for the appro- priate tool description. This section has been organized into sub-sections which ...

  • Page 43: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Replace guides 3. Valves mistimed 3. Retime engine 4. Piston rings worn — broken 4.
  • Page 44 Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. Drive — driven bevel gears damaged — worn 1. Replace gears 2. Backlash excessive 2. Adjust backlash 3. Tooth contact improper 3. Adjust contact 4.

  • Page 45: Removing Engine/Transmission

    Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT If the technician’s objective is to service/replace right- side cover oil seals, front output joint oil seal, rear out- PK160A put joint oil seal, and/or the oil strainer (from beneath 6.
  • Page 46 PK163A PK165A 11. From each side of the vehicle, loosen the eight cap screws securing the outside of the seat frame to the top of the main frame. PK109A 8. Remove the cap screw securing the thermostat bracket to the seat frame. Pull the gas tank filler neck vent line out from the seat frame.
  • Page 47 PK168 PK111A 15. Mark the cable tie location; then remove the cable tie 17. Remove the starter cable from the starter motor; then securing the O2 sensor wire to the frame. Disconnect remove the engine ground cable from the front the O2 sensor connector, then remove the two nuts starter motor mount.
  • Page 48 PK173A PK175 19. Remove the cap screw securing the gear shift arm to 21. Remove both large and small diameter coolant return the shift shaft. Note the alignment punch marks (A) hoses from the water pump. and (B) for assembly purposes. Measure and record the installed threaded set length (E) of the shift cable housing in the shift cable bracket.

  • Page 49: Servicing Engine

    Top-Side 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. The technician should use discretion and sound judgment. AT THIS POINT To service any one specific component, only limited dis- assembly of components may be necessary.
  • Page 50 NOTE: The manufacturer recommends the use of  new gaskets, lock nuts, and seals, and lubricating all internal components when servicing the engine/trans- mission. 1. Remove the cap screws securing the two tappet cov- ers. Remove the two tappet covers. Account for the O-rings.
  • Page 51 MD1131 FI616 6. Noting the timing marks for installing purposes, drop the sprocket off the camshaft. While holding the cam chain, slide the sprocket and camshaft out of the cyl- inder head. Account for an alignment pin.  NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase.
  • Page 52 CD211 FI622A 9. Remove the cylinder head from the cylinder, remove 12. Lift the cylinder off the crankcase taking care not to the gasket, and account for two alignment pins. allow the piston to drop against the crankcase. Account for the gasket and two alignment pins. FI623A FI624A AT THIS POINT...

  • Page 53: Servicing Top-Side Components

    2. Place the cylinder head cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head cover in a fig- ure-eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish.
  • Page 54 CC134D CC144D 2. Insert each valve into its original valve location. 3. Install the valve springs with the painted end of the spring facing away from the cylinder head.  NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head.
  • Page 55 3. Inspect the perimeter of each piston for signs of “blowby” indicated by dark discoloration. “Blowby” is caused by worn piston rings, excessive carbon in ring grooves, or an out-of-round cylinder. Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove.
  • Page 56 Installing Piston Rings 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a “heli-coil” insert. 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the 3.
  • Page 57 CC129D FI712 4. If any measurement exceeds the limit, the cylinder Inspecting Cam Chain Guide must be replaced. 1. Inspect cam chain guide for cuts, tears, breaks, or Measuring Camshaft Runout chips. NOTE: If the camshaft is out of tolerance, it must be ...

  • Page 58: Installing Top-Side Components

    2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced. NOTE: If the journals are worn, replace the cam-  shaft. Inspecting Camshaft Spring/Drive Pin 1. Inspect the spring and unloader pin for damage. FI626 NOTE: The piston should be installed so the IN ...
  • Page 59 NOTE: The two cylinder-to-crankcase nuts will be  tightened in step 9. FI714 7. Install the four cylinder head cap screws with wash- ers. Tighten only until snug. Note that the two cap FI622A screws on the right side of the cylinder head nearest the cam sprocket are longer than the two cap screws C.
  • Page 60 FI716 MD1359 12. With the alignment pin installed in the camshaft and 14. Place the C-ring into position in its groove in the cyl- the cam lobes directed down (toward the piston), inder head. place the camshaft in position and verify that the tim- ing mark on the magneto is visible through the inspection plug and that the timing marks on the camshaft sprocket are parallel with the valve cover...
  • Page 61 20. Install the cylinder head plug with the cupped end facing the camshaft and the opening directed down- wards. 21. Place the cam chain tensioner assembly and gasket into the cylinder. Tighten to 10 ft-lb (13.6 N-m). 22. Using a flat-blade screwdriver, turn the tensioner screw counterclockwise to apply tension to the cam chain;...

  • Page 62: Right-Side Components

    FI602 FI539 29. Install the spark plug and tighten securely; then install the timing inspection plug. Right-Side 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. The technician should use discretion and sound judgment.
  • Page 63 5. Remove the cap screws securing the magneto cover to the crankcase. Note the location of the two inter- nal cap screws and the two longer cap screws. FI551A 10. Remove starter idler gears and their respective shafts; then remove the starter motor. Account for an O-ring on the starter drive housing.

  • Page 64: Servicing Right-Side Components

    FI560 FI569 13. Remove the snap ring securing the output drive gear 3. Inspect the one-way bearing for chipped surfaces, to the output shaft and remove the gear noting that missing rollers, or discoloration. If any of the above the hub flange is directed toward the crankcase. conditions exist, replace the starter clutch assembly.
  • Page 65 FI576A FI580 INSPECTING STATOR/MAGNETO COVER ASSEMBLY 1. Inspect the stator for burned or discolored wiring, broken or missing hold-down clips, or loose cap screws. 2. Inspect the bearings in the magneto housing for dis- coloration, roughness when rotated, and secure fit in bearing bores.

  • Page 66: Installing Right-Side Components

    FI590 FI594 3. Install the new stator coil assembly and apply blue 2. Clean the bearing bores in the housing and inspect Loctite #243 to the three cap screws. Install and closely for cracks or shiny areas indicating bearing tighten to 13 ft-lb (17.7 N-m). movement.
  • Page 67 8. Install the rotor/flywheel and secure with the nut. Tighten to 107 ft-lb (145.1 N-m). C. Magneto Cover D. Water Pump  NOTE: Steps 1-8 in the preceding sub-section must precede this procedure. 9. Install two alignment pins and place the magneto cover gasket into position.

  • Page 68: Left-Side Components

    Removing Left-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover 1. Remove the cap screws securing the V-belt cover to the clutch cover; then remove the V-belt cover. Account for two alignment pins and a gasket. FI539 12. Install the water pump cover with a new O-ring and secure with the four cap screws.
  • Page 69 MD1033 KC132 4. Remove the movable drive face and spacer. Account 6. Remove the fixed drive face. for the movable drive face rollers and outer drive face cover. MD1094 7. Remove the nut holding the driven pulley assembly; then remove the driven pulley assembly. MD1035 MD1034A MD1068...
  • Page 70 9. Remove the cap screws holding the inner clutch cover onto the left-side crankcase half. Note the positions of the different-length cap screws for installing purposes. FI733 13. Remove the two Phillips head screws securing the bearing retainers to the inner clutch cover housing. Remove the retainers.
  • Page 71 14. Remove the oil pump drive gear cap screw. MD1286A 12. Remove the left-hand threaded nut holding the cen- MD1018 trifugal clutch assembly. 15. Remove oil pump drive gear. Account for the pin. CAUTION Care must be taken when removing the nut; it has “left- hand”...

  • Page 72: Servicing Left-Side Components

    MD1020 MD1208 AT THIS POINT AT THIS POINT To service clutch components, see Servicing Left-Side To service center crankcase components only, proceed Components sub-section. to Separating Crankcase Halves. G. Oil Pump/Oil Strainer  NOTE: Steps 1-17 for the removal of items A Servicing Left-Side through F in the preceding sub-sections must precede Components...
  • Page 73 INSPECTING DRIVE CLUTCH ASSEMBLY 1. Slide the sheave plate out of the movable drive sheave. Make note of each drive face plate damper orientation before removing. Check for excessive wear, warping or any cracks. Replace as necessary. Check the internal splines of the sheave plate for excessive or abnormal wear.

  • Page 74: Installing Left-Side Components

    DRIVEN PULLEY ASSEMBLY NOTE: The driven pulley assembly is only service-  able as an assembly. Installing Left-Side Components A. Oil Strainer/Oil Pump 1. Place the oil strainer into position beneath the crank- case. Tighten the Phillips-head screws securely. FI727 MD1337 FI728 2.
  • Page 75 MD1060 MD1017 4. Place the thrust washer and drive pin into position on the oil pump shaft, install the oil pump driven gear making sure the recessed side of the gear is directed inward, and secure with a new snap ring. ...
  • Page 76 9. Install the one-way clutch making sure that the green 3. Place a new bearing into position with the sealed side dot or the word OUTSIDE is directed away from the of the bearing facing down; then using an appropri- crankcase.
  • Page 77 FI739A MD1342 9. Place the driven pulley assembly into position and secure with the nut (threads coated with red Loctite #271). Tighten to 85 ft-lb (115.6 N-m). FI740A 6. Install two alignment pins and place the clutch cover gasket into position. Install the inner clutch cover. MD1068 MD1115 7.

  • Page 78: Center Crankcase Components

    KC137 FI743 NOTE: The arrows on the V-belt should point in NOTE: At this point, the cap screw can be removed   direction of engine rotation. from the driven pulley face. 12. Making sure the movable drive face rollers are in 14.

  • Page 79: Disassembling Crankcase Half

    FI722 FI639A 2. Using Crankcase Separator/Crankshaft Remover and 1. Remove the secondary driven shaft assembly (A) tapping lightly with a rubber mallet, separate the noting the location of the front and rear bearing crankcase halves. Account for two alignment pins. locating pins and the center bearing locating ring.
  • Page 80 5. Remove the countershaft assembly (E) along with the shift fork assembly. FI641A 3. Remove the driveshaft (C); then pull the shift fork locating shaft (D) out of the crankcase locating boss FI662 and allow the shift forks to disengage from the gear 6.

  • Page 81: Servicing Center Crankcase Components

    Checking Tooth Contact 8. Remove the secondary drive gear/secondary driven gear retaining nut. From inside the crankcase using a NOTE: After correcting backlash of the secondary  rubber mallet, drive out the output shaft assembly. driven bevel gear, it is necessary to check tooth con- Account for the output shaft, a shim, a washer, and tact.
  • Page 82 Correcting Tooth Contact 2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal. NOTE: If tooth contact pattern is comparable to the  correct pattern illustration, no correction is necessary. If tooth contact pattern is comparable to an incorrect pat- tern, correct tooth contact according to the following chart: Tooth Contact...
  • Page 83 H1-006 FI665 2. Acceptable width range must be within specifica- 3. Remove the low driven gear washer; then remove the tions. low driven gear along with the bearing and bushing. COUNTERSHAFT CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces.
  • Page 84 FI669 FI671A 5. Remove the circlip securing the high driven gear; then remove a washer, the high driven gear along with the bearing and bushing, and remove the high driven washer. FI670 2. Install the high/low shift dog (6) on the countershaft and secure with snap-ring (7);...

  • Page 85: Assembling Crankcase Half

    FI666 FI662 4. Place the reverse driven bushing (13) onto the shaft; NOTE: The countershaft assembly is now ready to  then install the bearing (14), gear (15), and splined be installed. washer (16). Secure with a snap-ring. Assembling Crankcase Half ...
  • Page 86 MD1333 FI658 3. Apply a liberal amount of oil to the crankshaft bear- 6. Align the shift cam fork slots with the shift fork shaft ing. Using a propane torch, heat the bearing until the locating boss and with a washer on each end, install oil begins to smoke;...
  • Page 87 8. Align the shift forks to allow engagement with the shift cam; then engage the shift forks and slide the shift fork shaft into the locating boss in the crank- case. FI645 11. Install the secondary output driveshaft assembly into the crankcase half making sure the front and rear bearing alignment pins are seated in the recesses;...

  • Page 88: Installing Engine/Transmission

    Joining Crankcase Halves 1. Verify that the two alignment pins (A) are in place and that both case halves are clean and grease free. Apply Loctite #5900 or suitable substitute sealant to the mating surfaces. Place the left-side half onto the right-side half.
  • Page 89 1. Install the engine bracket with weld nuts to the front 6. Install the large and small diameter coolant return of the engine using the through bolt and nut. Finger hoses to the water pump. Install the large and small tighten only at this point.
  • Page 90 PK174 PK171 8. With the fuel injector O-ring in place, install the 10. Place the throttle body into the intake boot and injector and fuel rail onto the cylinder head; then secure it with the clamp. Correctly route and secure secure using the two cap screws.
  • Page 91 16. Loosely install the cap screws from the front of the seat frame to the main frame. PK169 PK165A 17. Install new patch-lock cap screws and nuts securing the front and rear ROPS assemblies together. Tighten the ROPS fasteners to 47 ft-lb (63.9 N-m). PK168 13.
  • Page 92 22. Install both left and right-rear splash panels; then secure them using the reinstallable plastic rivets. Install both left and right side panel assemblies (see Dashboard). PK161A PK108A 23. Pour the recommended amount of oil and coolant into the engine and radiator. PK162 21.

  • Page 93: Fuel/Lubrication/Cooling

    Fuel/Lubrication/ Cooling TROUBLESHOOTING 1. Verify that the electric fuel pump is operating by lis- tening for a “whirring” sound for several seconds after the ignition switch is turned to the ON position. If no sound can be heard, see EFI Sensors/Compo- nents in Electrical System.

  • Page 94: Gas Tank

    INSTALLING 1. Install the throttle body into the intake manifold boot and secure with the clamp. Tighten to 30 in.-lb (3.4 N-m). 2. Connect the throttle cable to the throttle body; then install the throttle arm cover and secure it to the throttle body with the two screws.
  • Page 95 5. Place a shop towel under the fuel line connector; then squeeze the release tab to remove. Disconnect the fuel pump harness connector. PK191 2. Connect the fuel line to the fuel pump; then verify the connector is fully seated to the fuel pump junc- ture.

  • Page 96: Oil Pump

    2. Connect the Oil Pressure Test Kit to the oil pressure test port. PK188A 5. Secure the passenger side under seat storage tray using four cap screws and tighten securely. KC370A  NOTE: Some oil seepage may occur when installing the oil pressure gauge.

  • Page 97: Liquid Cooling System

    Liquid Cooling System When filling the cooling system, use premixed anti- freeze. Verify the coolant level in the reservoir tank is between the FULL and LOW indicator lines. Fill as needed. While the main cooling system is being filled, air pockets may develop.
  • Page 98 4. Loosen the clamps; then remove the upper and lower main coolant hoses from the radiator. Remove the reservoir hose (B) from the right side of the filler neck and the bleed hose (A) from the back of the filler neck. PK201A 6.
  • Page 99 THERMOSTAT Removing 1. Drain approximately one quart of coolant from the cooling system. 2. Remove the two cap screws securing the thermostat housing to the bracket. Account for a thermostat with seal and O-ring installed in the thermostat housing cover. PK201A 2.

  • Page 100: Troubleshooting

    PK203 PK204A 2. Fill the cooling system with the recommended Installing amount of antifreeze. Check for leakage. 1. Position the fan assembly on the radiator bracket; COOLING FAN then secure with existing hardware. Removing NOTE: Secure the radiator bleed hose using the ...

  • Page 101: Electrical System

    After being in service, batteries require regular cleaning and recharging in order to deliver peak performance and Electrical System maximum service life. The following procedures are rec- ommended for cleaning and maintaining lead-acid batter- ies. Always read and follow instructions provided with battery chargers and battery products.

  • Page 102: Ignition Switch

    NOTE: The maintainer/charger will charge the bat-  tery to 95% capacity at which time the Maintenance Ignition Switch Charge Indicator (D) will illuminate and the main- tainer/charger will change to pulse/float maintenance. If the battery falls below 12.9 DC volts, the charger The ignition switch connector can be accessed by remov- will automatically start again at the first step of the ing the front left splash panel.

  • Page 103: Ignition Timing

    RESISTANCE Ignition Timing CAUTION Always disconnect the battery when performing resis- tance tests to avoid damaging the multimeter. The ignition timing cannot be adjusted; however, verify- NOTE: For these tests, the meter selector should be  ing ignition timing can aid in troubleshooting other com- set to the OHMS position.

  • Page 104: Switches

    VOLTAGE (Brake Light) Switches Component data can be retrieved using the Dealer Diag- nostic Service. Utilize the Sensor Data screen. NOTE: The ignition switch must be in the ON posi-  SEAT BELT LIMITER SWITCH tion. 1. Remove the passenger seat. Locate the switch con- 1.
  • Page 105 3. When the lever is depressed, the meter must read continuity. When released, the meter must read show OFL.  NOTE: If the meter readings are not as described, replace the switch. VOLTAGE (Headlight) 1. Connect the red meter lead to the white wire; then connect the black meter lead to the black wire.

  • Page 106: Fan Motor

    4. Depress the reverse override switch. The meter must NOTE: The fuses are located in a power distribu-  show near zero volts. tion module under the hood. 5. Select “LOCK” on the drive select switch. The meter NOTE: Make sure the fuses are returned to their ...

  • Page 107: Efi Sensors/Components

    CRANKSHAFT POSITION (CKP) 2. Set the meter to the OHMS position. To test the pri- mary side of the relay, connect the meter leads to the SENSOR number 85 and 86 pins. The meter will read approxi- Resistance mately 135 ohms (4-pin relay) or 103 ohms (5-pin relay).
  • Page 108 4. Connect the black test lead to battery ground; then, NOTE: Neither the sensor nor the thermometer  on the harness side of the connector, place the red should be allowed to touch the bottom of the con- test lead to the black/green wire. With the meter set tainer or inaccurate readings will occur.
  • Page 109 Removing FUEL PUMP/FUEL LEVEL SENSOR 1. Remove the key from the ignition switch. Component data can be retrieved using the Dealer Diag- nostic Service. Utilize the Sensor Data screen. ! WARNING The fuel pump and fuel level sensor are only service- ...
  • Page 110 Replacing Installing To replace the fuel level sensor, use the following proce- 1. Place the fuel pump assembly into the gas tank with dure: a new gasket aligning the match marks; then secure with the six screws. Tighten securely. 1. Cut the two blue wires (A) in the location shown. NOTE: It is important to install the fuel pump with ...
  • Page 111 Output Voltage NOTE: When replacing the sensor after testing,  make sure the arrow marking is directed up. NOTE: Needle adapters or Maxi-Clips will be  required on the multimeter leads as the following tests THROTTLE POSITION SENSOR (TPS) are made with the sensor connected: Component data can be retrieved using the Dealer Diag- nostic Service.

  • Page 112: Rpm Limiter

    Stator Coil VOLTAGE (AC Generator — No Load) The black three-pin connector is located on the right side of the engine. PK301 NOTE: If the throttle body, ECM, TPS, or ISC are  replaced, the EFI system must be synchronized. Use the following procedure: 1.

  • Page 113: Starter Motor

    3. Slowly increase RPM. The voltage should increase with the engine RPM. The charging voltage should be greater than resting battery voltage (key off). The charging voltage should not exceed a maximum of 15.0 DC volts. CAUTION Do not run the engine at high RPM for more than 10 seconds. ...

  • Page 114: Electronic Control Module (Ecm)

    1. Turn the ignition switch ON. 2. Depress and hold both left and right buttons together for approximately three seconds until “DIAGNOS- TIC” appears on the LCD. PK304B 5. Engage the starter switch and observe the multime- ter. The meter must show battery voltage. ...
  • Page 115 Coolant (COOLANT) MAP (AIR PRESS) WT591 WT602 Display: Engine coolant temperature as measured by the Display: MAP in millibars and in./Hg. ECT sensor. DTC: P0107, P0108 DTC: P0116, P0117, P0118, P0119 Usage: Verify barometric pressure signal correct. Usage: Monitor coolant temperature to verify the follow- ing: NOTE: Local barometric pressure is given in in./Hg ...
  • Page 116 Fuel Sensor (FUEL) Speedometer (SPEED) WT545 WT543 Display: Fuel level signal from the fuel level sensor. Display: Vehicle speed signal. DTC: C1400, C1401, C1402 DTC: P0500 Usage: Check output of the fuel level sensor.* Usage: Verify speedometer sensor signal from the fol- lowing: 1.
  • Page 117 DIAGNOSTIC TROUBLE CODES (DTC) Code List If an EFI or related chassis component fails or an out-of- NOTE: Each of the following numerical codes will  tolerance signal is detected by the ECM, a diagnostic have a one-letter prefix of C, P, or U. A “C” prefix trouble code (DTC) will be generated in the ECM and denotes a chassis malfunction, a “P”...
  • Page 118 Code Fault Description Possible Cause Fault Recovery Method P0500 Vehicle Speed-Sensor Sensor circuit signal intermittent or missing Correct condition*, start and drive the vehicle* P0508 IAC System Circuit Low/SG IAC interconnect harness shorted to chassis ground Correct condition* P0509 IAC System Circuit High/Open IAC disconnected or the interconnect harness shorted to battery Correct condition* power...

  • Page 119: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug(s) defective 2. Replace plug(s) 3. CKP sensor defective 3. Replace CKP sensor 4. ECM defective 4. Replace ECM Problem: Spark plug fouled with carbon Condition Remedy 1.

  • Page 120: Drive System

    Drive System GENERAL INFORMATION Gear cases are 3.6:1.  NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut. SPECIAL TOOLS A number of special tools must be available to the techni- PK305 cian when performing service procedures in this section.
  • Page 121 INSTALLING 5. Remove the cable tie securing the actuator wiring Note the location for assembly purposes. Disconnect 1. Lubricate the O-rings on the actuator; then ensure all the actuator connector. Remove the cap screw secur- mounting surfaces are clean and free of debris. ing the coolant pipe bracket to the frame.

  • Page 122: Front Differential

    Front Differential REMOVING 1. Remove the front belly panel. 2. Remove the drain plug and drain the gear lubricant into a drain pan; then install the plug and tighten to 45 in.-lb (5.1 N-m). PK035 PK029A 3. Remove the hubs (see Hub in this section, steps 1-5). 4.
  • Page 123 PR222 PK230A 7. Support the axle to prevent it from dropping or hang- 11. Remove the upper differential mounting cap screw ing. and lock nut. Discard the lock nut. CAUTION The axle must be supported. If the axle is allowed to drop or hang, damage to the inner CV joint may occur.
  • Page 124 PK313 PK038A Disassembling Input Shaft 1. Remove the actuator (see Front Drive Actuator sec- tion). 2. Remove the slotted aluminum plug and account for the O-ring. Remove the differential locking shaft cir- clip. Account for the circlip, spring retainer, and spring.
  • Page 125 PK042 PK045 6. From the opposite side of the housing, use an appro- 2. Install the input shaft seal, making sure it is fully priate sized bearing driver to press the bearing out of seated in the housing. the housing. GC014 3.
  • Page 126 4. With the dowel pin in place, set a new gasket into position and secure the pinion housing to the differ- ential with the three cap screws. PK205 2. Using a criss-cross pattern, loosen and remove the cap screws securing the differential cover. 3.
  • Page 127 NOTE: Unstake the lock collar if evidence of the  process was performed in a previous service. KX177 PK210 2. Using the Pinion Gear/Shaft Removal Tool and a hammer, remove the pinion gear from the gear case housing. PK208A 6. Place the differential with the open side down; then lift the housing off the spider assembly.
  • Page 128 3. Using a propane torch, heat the gear case housing to approximately 200° F (93° C); then install the pinion assembly. 4. Install a new lock collar and tighten to 125 ft-lb (169.5 N-m). Stake the collar into the gear case. PK216 PK214 PK217...
  • Page 129 Shimming Procedure/Shim Selection Case-Side Shims (Backlash) 3307-304 0.051 3307-305 0.055 3307-306 0.059 3307-307 0.063 3307-308 0.067 Cover-Side Shims (Ring Gear End-Play) 3306-132 0.039 3306-133 0.042 3306-134 0.046 PK208B 3. Install the bearing flange onto the gear case cover 3306-135 0.051 making sure the alignment/locating pin engages the 3306-136 0.055...
  • Page 130 PK208A PK220B 5. Place the appropriate Backlash Measuring Tool (24 Ring Gear End-Play spline axle) into the splines of the ring gear and After correcting backlash, ring gear end-play can be install a dial indicator making sure it contacts the adjusted.
  • Page 131 GC031A PK223A PK222 PK224 2. Place the selected (end-play) shim, chamfered side 4. Verify the bearing flange is properly aligned with the toward the gear (if applicable), onto the cover side of different cover and fully seated. With the two dowel the ring gear.
  • Page 132 5. Keeping the bearing flange pressed against the cover, install the assembly onto the differential housing. While this is being performed, align the internal splines of the differential lock coupler to the external splines of the housing. Secure the cover to the hous- ing with existing cap screws.
  • Page 133 2. Grease the input shaft and front propeller shaft splines. Insert the tension spring (A) into the propel- ler shaft. Place the differential assembly into position in the frame engaging the front propeller shaft; then install the top mounting cap screw and new lock nut. Do not tighten at this time.

  • Page 134: Drive Axles

    Drive Axles REMOVING REAR DRIVE AXLE 1. Lift the vehicle using a suitable lift to elevate the wheels off the ground. Remove the hubs (see Hub in this section). 2. Remove the cap screw and lock nut securing the knuckle to the upper A-arm. Discard the lock nut. PK233 6.
  • Page 135 REMOVING FRONT DRIVE AXLE NOTE: For removing a front drive axle, see Front  Differential in this section. CLEANING AND INSPECTING AXLES  NOTE: Always clean and inspect the drive axle components to determine if any service or replace- ment is necessary. 1.
  • Page 136 PK237 PK240A 6. Using the Boot Clamp Tool, install and secure the large outside diameter clamp. PK241 3. Note the orientation of the CV joint to the half-shaft. Remove the snap ring securing the joint to the shaft. PK238 Remove the CV joint; then remove the boot. Removing Inboard CV Joint 1.
  • Page 137 PK242A PK243A 3. Slide the CV housing onto the CV joint; then install a NOTE: To ensure proper axle seating, give it a light  new circlip stop ring (A). Slide the new boot into pull; the axle should remain “clipped” in place. position;...

  • Page 138: Rear Gear Case

    4. Remove the vehicle from the lift. 4. Pull the rear propeller shaft boots away from the input shaft and rear engine flange. Holding the pro- 5. Check the front differential lubricant level and add peller shaft in place, disengage the gear case from lubricant as necessary.
  • Page 139 PK245A PK248 2. Remove the four cap screws securing the rear caliper 5. Remove the ring gear from the housing. Account for mount to the gear case. Record the locations of the the housing side shim. two different-length cap screws, which require patch-lock (A).
  • Page 140 CAUTION Protective equipment should be worn, as severe injury or burns could result. 7. Using a propane torch, heat the gear case to approxi- mately 200° F (93° C). Carefully using the Pinion Gear/Shaft Removal tool, remove the pinion gear. PK255 PK252 8.
  • Page 141 PK258 PK259 3. Place the pinion gear shim into position; then, using CLEANING AND INSPECTING a set of press blocks, press the pinion gear into a new 1. Wash all parts in parts cleaning solvent and dry with bearing. compressed air. ! WARNING Always wear safety glasses when working with com- pressed air.
  • Page 142 5. Using soft jaws, secure the gear case into a vise. Using a propane torch, heat the gear case to approxi- mately 200° F (93° C); then carefully install the pin- ion gear assembly into the case. Install the lock collar to secure the pinion into the case.
  • Page 143 7. Place the correctly sized case side shim onto the ring gear; then install into the gear case. Place the cover side shim onto the ring gear. PK245A INSTALLING 1. Place the spring into the input shaft; then position the PK262 gear case into position below the frame mounts.

  • Page 144: Hub

    PK265 PK130 4. Using new patch lock cap screws, install and secure 3. Remove the hub nut securing the hub. Continue to the rear brake caliper to the mount and tighten the step 4 to remove the front hubs. screws to 19 ft-lb (25.8 N-m). Install the drive axles 4.
  • Page 145 INSTALLING Rear 1. Secure the brake disc to the hub (front) with the four cap screws or to the rear input shaft with five cap screws coated with red Loctite #271. Tighten to 25 ft-lb (34 N-m). 2. Apply grease to the splines of the front hub. If installing the rear brake disc, at this point reinstall the rear gear case (see INSTALLING).

  • Page 146: Hydraulic Brake Caliper

    5. Secure the brake calipers to the knuckle with two new “patch-lock” cap screws tightened to 19 ft-lb (25.8 N-m). PK004B CAUTION Brake fluid is highly corrosive. Do not spill brake fluid PK106B on any surface of the vehicle and do not reuse brake 6.
  • Page 147 PK271 PK275 ! WARNING Make sure to hold the towel firmly in place or the piston could be ejected from the housing causing injury. 8. Using an appropriate seal removal tool, carefully remove the seals from the brake caliper housing. Discard all seals, O-rings, and crush washers.
  • Page 148 6. Secure the brake pads to the caliper with the brake 2. Press the piston into the caliper housing using hand pad pins. Apply blue Loctite to the threads of the pressure only. Completely seat the piston and dust pins; then tighten to 13 ft-lb (17.7 N-m). seal;...
  • Page 149 4. Remove the master cylinder. Discard the three crush washers as new ones are required for assembly. 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.

  • Page 150: Troubleshooting Drive System

    Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shaft serration worn — broken 1. Replace shaft Problem: Power not transmitted from engine to either front wheel Condition Remedy 1. Secondary drive - driven gear teeth broken 1.

  • Page 151: Suspension

    Rear 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 REAR leaking. PK283A D.
  • Page 152 PK317 PK319 3. Remove the cotter pin and castle nut securing the tie rod end to the knuckle; then remove the tie rod end from the knuckle. Account for the washer. 4. Remove the cap screws securing the ball joints to the knuckle.
  • Page 153 PK320 PK319 3. Route the brake hose along the upper A-arm. Secure CLEANING AND INSPECTING with hose and clamps. 1. Clean all A-arm components in parts-cleaning sol- vent. 2. Clean the ball joint mounting hole of all residual Loctite, grease, oil, or dirt for installing purposes. 3.

  • Page 154: Rear A-Arms

    PK234A PK106B 7. Install the tie rod end and secure with the washer 10. Install the wheels and using a crisscross pattern, and nut (coated with red Loctite #271). Tighten to tighten the wheel nuts in 20 ft-lb (27.2 N-m) incre- 25 ft-lb (34 N-m);...
  • Page 155 PK285 PK287 4. Remove the cap screws and lock nuts securing the 5. Remove the cap screws securing the rear fascia to the shock absorber to the frame and lower A-arm; then frame. Remove the cap screws and lock nuts secur- remove the A-arm.

  • Page 156: Wheels And Tires

    TIRE INFLATION PRESSURE 3. Slide the knuckle onto the drive axle and into posi- tion on the A-arms; then secure the knuckle with dust Front and rear tire inflation pressure should be 82.7 kPa seals and pivot bushing to the A-arms with cap (12 psi).

  • Page 157: 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. Rear shock absorbers too soft 4. Check and adjust air pressure in shocks Problem: Suspension too stiff Condition Remedy...
  • Page 158 NOTES...

Table of Contents

Save PDF