General Information/Foreword; Specifications - Tracker Off-Road 500S Service Manual

General Information/
Foreword
This Service Manual contains service, maintenance, and
troubleshooting information for the 2021 500S model.
The complete manual is designed to aid service personnel
in service-oriented applications.
This manual is divided into sections. Each section covers
a specific vehicle component or system and, in addition
to the standard service procedures, includes disassem-
bling, inspecting, and assembling instructions. When
using this manual as a guide, the technician should use
discretion as to how much disassembly is needed to cor-
rect any given condition.
This service manual is designed primarily for use by a
basic level technician. The procedures found in this man-
ual are of varying difficulty, and certain service proce-
dures in this manual require one or more special tools to
be completed. The technician should use sound judgment
when determining which procedures can be completed
based on their skill level and access to appropriate special
tools.
NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is nec-
essary.
When replacement of parts is necessary, use only genuine
parts. They are precision-made to ensure high quality and
correct fit. Refer to the appropriate Illustrated Parts Man-
ual for the correct part number, quantity, and description.
All publications and decals display the words Warning,
Caution, Note, and At This Point to emphasize important
information. The symbol ! WARNING identifies
personal safety-related information. Be sure to follow the
directive because it deals with the possibility of serious
personal injury or even death. A CAUTION identifies
unsafe practices which may result in vehicle-related dam-
age. Follow the directive because it deals with the possi-
bility of damaging part or parts of the vehicle. The
symbol  NOTE: identifies supplementary information
worthy of particular attention. The symbol
THIS POINT directs the technician to certain and
specific procedures to promote efficiency and to improve
clarity.
At the time of publication, all information, photographs,
and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes
only and are not designed to depict actual conditions.
Because we constantly refine and improve our products,
no retroactive obligation is incurred.
All materials and specifications are subject to change
without notice.
2

Specifications

NOTE: Specifications subject to change without notice.

Dry Weight (approx)
ROPS Tested Curb Weight
Length (overall)
Height (overall)
Width (overall)
Tire Size
Tire Inflation Pressure (w/cargo)
Spark Plug Type
Spark Plug Gap
Gas Tank Capacity
Coolant Capacity
Front Differential Capacity (change)
Rear Drive Capacity (change)
Engine Oil Capacity (approx)
Gasoline (recommended)
Engine Oil (recommended)
Front Differential/Rear Drive Lubricant
(At level plug hole)
Drive Belt Width
Brake Fluid
Taillight/Brake Light/Reverse light
Headlight (high beam/low beam)
Ignition Timing
Spark Plug Cap
Ignition Coil Resistance
Ignition Coil Primary Voltage
Stator Coil Resistance
AC Generator Output (no load)
Crankshaft Position Sensor AC Voltage
AT
Valve Face Diameter
Valve/Tappet Clearance
(cold engine)
Valve Guide/Stem
Clearance (max)
Valve Guide Inside Diameter
Valve Seat Angle
Valve Spring Free Length (min)
Valve Spring Tension @ 35.2 mm
CHASSIS
496.7 kg (1095 lb)
997.9 kg (2200 lb)
270.3 cm (106.4 in.)
194.8 cm (76.7 in.)
143.3 cm (56.4 in.)
(front) 25 x 8-12
(rear) 25 x 10-12
(front) 82.7 kPa (12 psi)
(rear) 137.9 kPa (20 psi)
MISCELLANEOUS
NGK CR6E
0.7-0.8 mm (0.028-0.031 in.)
32.2 L (8.5 U.S. gal.)
2.5 L (2.65 U.S. qt)
250 ml (8.45 fl oz)*
230 ml (7.78 fl oz)*
2.8 L (3.0 U.S. qt) —
Overhaul
2.4 L (2.5 U.S. qt) —
Change
87 Octane Regular
Unleaded
ACX All Weather Synthetic
SAE Approved 80W-90
Hypoid
28.5 mm (1.12 in.)
DOT 4
12V/5W/21W
12V/60W/55W
ELECTRICAL SYSTEM
12° BTDC @ 1425 RPM
4000-6000 ohms
(primary) Less than 1 ohm
(secondary) N/A
Battery Voltage
(CKP Sensor) 104-156 ohms
(AC generator) Less than 1 ohm
75 AC volts @ 5000 RPM
2.0 volts or more
VALVES AND GUIDES
(intake) 30.6 mm
(exhaust) 27.0 mm
(intake) 0.10 mm
(exhaust) 0.17 mm
(intake) 0.04 mm
(exhaust) 0.06 mm
5.000-5.012 mm
(intake/exhaust) 45°
42.8 mm
18.6 kg ( 41.1 lb)