Testing Engine Compression - Tracker Off-Road 500S Service Manual

FI605A
FI603
2. Rotate the crankshaft to the TDC position on the
compression stroke by aligning the rotor mark to the
crankcase marking.
FI709
NOTE: At this point, the rocker arms and adjuster

screws must not have pressure on them.
CHECKING
Using a feeler gauge, check each valve/tappet clearance. If
clearance is not within specifications, loosen the jam nut
and rotate the tappet adjuster screw until the clearance is
within specifications. Tighten each jam nut to 7 ft-lb (9.5
N-m) after completing the adjustment.
CAUTION
The feeler gauge must be positioned at the same angle
as the valve and valve adjuster for an accurate mea-
surement of clearance. Failure to measure the valve
clearance accurately could cause valve component
damage.
VALVE/TAPPET CLEARANCE
Intake 0.1016 mm (0.004 in.)
Exhaust 0.1778 mm (0.007 in.)
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;
then rotate the tappet adjuster screw clockwise until
friction is felt.
C. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
D. While holding the valve adjuster handle in place,
rotate the valve adjuster dial counterclockwise until
proper valve/tappet clearance is attained.
NOTE: Refer to the specifications in CHECKING

for the proper valve/tappet clearance.
NOTE: Rotating the valve adjuster dial counter-

clockwise will open the valve/tappet clearance by 0.05
mm (0.002 in.) per mark.
E. While holding the adjuster dial at the proper clear-
ance setting, tighten the jam nut securely with the
valve adjuster handle.
3. Install the spark plug; then install the timing inspec-
tion plug and magneto cover plug.
4. Place the two tappet covers with O-rings into posi-
tion. Tighten the cap screws to 8 ft-lb (10.9 N-m).
Testing Engine
Compression
NOTE: The engine should be warm (operating tem-

perature) and the battery fully charged for an accu-
rate compression test. The throttle must be in the
wide-open throttle (WOT) position. In the event the
engine cannot run up to operating temperature, cold
values are included.
NOTE: The seat must be removed for this proce-

dure.
1. Remove the high tension lead from the spark plug.
2. Using compressed air, blow any debris from around
the spark plug.
! WARNING
Always wear safety glasses when using compressed
air.
3. Remove the spark plug; then attach the high tension
lead to the plug and ground the plug on the cylinder
head well away from the spark plug hole.
4. Attach the Compression Tester Kit.
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