Installing Engine/Transmission; Joining Crankcase Halves - Tracker Off-Road 500S Service Manual

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.
FI639B
NOTE: Be sure to apply silicone to the inside radius

of all cap screw locations and the entire surface of the
internal cap screw bosses.
FI639D
2. Using a plastic mallet, lightly tap the case halves
together until cap screws can be installed.
3. From the right side, install the crankcase cap screws
noting the location of the different-sized cap screws;
then tighten only until snug.
 NOTE: Rotate the shafts back and forth to ensure
no binding or sticking occurs while tightening the cap
screws.
86
MD1008
4. From the left side, install the remaining crankcase
cap screws; then tighten only until snug.
NOTE: Rotate the shafts back and forth to ensure

no binding or sticking occurs while tightening the cap
screws.
CC871
5. In a crisscross pattern, tighten the 8 mm cap screws
until the halves are correctly joined; then tighten to
21 ft-lb (28.6 N-m).
NOTE: Rotate the shafts back and forth to ensure

no binding or sticking occurs.
6. In a crisscross pattern, tighten the 6 mm cap screws
to 10 ft-lb (13.6 N-m).
NOTE: Rotate the shafts back and forth to ensure

no binding or sticking occurs.
AT THIS POINT
After completing center crankcase components, pro-
ceed to Installing Right-Side Components, to Installing
Left-Side Components, and to Installing Top-Side Com-
ponents.
Installing Engine/
Transmission
NOTE: The manufacturer recommends new gas-

kets, patch-lock cap screws, lock nuts, and O-rings be
installed whenever servicing the vehicle.