Removing Engine/Transmission - Tracker Off-Road 500S Service Manual

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-
put joint oil seal, and/or the oil strainer (from beneath
the engine/transmission), the engine/transmission does
not have to be removed from the frame.
Support the vehicle on a suitable lift or jack stands allow-
ing room to work.
! WARNING
Make sure the vehicle is solidly supported on the sup-
port stands to avoid injury.
1. Remove the seat, engine compartment panel, and the
battery box cover; then disconnect the negative bat-
tery cable and secure it away from the battery. Tilt
the cargo bed back.
2. Drain the oil and coolant.
3. Remove both left and right side panel assemblies
(see Dashboard).
4. Remove both left and right side rear splash panels.
PK108A
5. Loosen the two clamps securing the air inlet and out-
let tubes to the air box assembly; then remove the
crankcase breather hose from the air box. Remove
the two cap screws securing the air box to the seat
frame. Remove the air box assembly.
PK160A
6. Remove the harness from the seat frame. Mark the
location of the driver's seat belt limiter switch con-
nector; then disconnect the connector.
PK161A
PK162
7. Remove the rear gear case bladder from the center
splash panel; then remove the cap screw and nut
securing the CVT exhaust duct to the seat frame.
Loosen the clamp securing the CVT exhaust duct to
the front of the CVT housing. Loosen the CVT inlet
clamp; then remove the cap screw and lock nut
securing the tube to the frame. Remove both ducts.
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