Tracker Off-Road XTR1000 Service Manual
  1. Manuals
  2. Brands
  3. Tracker Off-Road Manuals
  4. Offroad Vehicle
  5. XTR1000
  6. Service manual

Tracker Off-Road XTR1000 Service Manual

Hide thumbs Also See for XTR1000:
Table of Contents

Advertisement

Quick Links

SERVICE MANUAL
p/n: 2262-827
7/19
XTR1000

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the XTR1000 and is the answer not in the manual?

Questions and answers

Related Manuals for Tracker Off-Road XTR1000

Summary of Contents for Tracker Off-Road XTR1000

  • Page 1 SERVICE MANUAL p/n: 2262-827 7/19 XTR1000...

  • Page 2: Table Of Contents

    Table of Contents General Information/Foreword ......... 2 Fuel Pump ..............70 Specifications ............... 2 Fuel/Vent Hoses............70 Torque Specifications ........... 3 Liquid Cooling System ..........70 Torque Conversions (ft-lb/N-m) ........4 Radiator...............71 Drive Belt Break-In Procedure ........4 Thermostat ..............73 Gasoline — Oil — Lubricant ......... 4 Fans ................73 Preparation for Storage ..........

  • Page 3: General Information/Foreword

    NOTE: Specifications subject to change without notice.  This Service Manual contains service, maintenance, and CHASSIS troubleshooting information for the 2020 XTR1000 model. Dry Weight (approx) 821 kg (1812 lb) The complete manual is designed to aid service personnel ROPS Tested Curb Weight 1179.4 kg (2600 lb)

  • Page 4: Torque Specifications

    CYLINDERS, PISTONS, AND RINGS Torque Part Part Bolted to Piston/Cylinder Clearance .035-.060 mm ft-lb (max) 0.120 mm EXHAUST COMPONENTS Cylinder Bore 80.000-80.010 mm Piston Diameter 79.950-79.965 mm Manifold Engine Muffler Transaxle Bracket Bore x Stroke 80.0 x 66.2 mm Spark Arrester Muffler 72 in-lb.

  • Page 5: Torque Conversions (Ft-Lb/N-M)

    Torque Part Part Bolted to ft-lb N-m Torque Conversions STEERING COMPONENTS (ft-lb/N-m) Steering Rack Mount Bracket Mount Bracket Frame EPS Bracket EPS Unit Lower Steering Shaft (Splined End) Steering Rack Lower Steering Shaft (Adj. Yoke) Self ft-lb ft-lb ft-lb ft-lb Lower Steering Shaft (Upper EPS Unit 35.4...

  • Page 6: Preparation For Storage

    RECOMMENDED TRANSAXLE ! WARNING LUBRICANT Do not overflow gasoline when filling the gas tank. A The recommended transaxle lubricant is Synthetic Tran- fire hazard could materialize. Always allow the engine to saxle Fluid with EP. This lubricant meets all of the lubri- cool before filling the gas tank.

  • Page 7: Preparation After Storage

    CAUTION Preparation after Storage Before installing the battery, make sure the ignition switch is in the OFF position. Taking this vehicle out of storage and correctly preparing 7. Check the entire brake systems (fluid level, pads, it will ensure many miles and hours of trouble-free rid- etc.), all controls, headlights, taillight, brake light, ing.

  • Page 8: 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: A.

  • Page 9: Spark Arrester

    WC929 XX229 3. Install the spark arrester assembly and secure the 7. Reinstall the air filter cover, then turn it approxi- screw. Tighten to 72 in.-lb. mately 1/16 of a turn clockwise to seat it to the hous- ing. Verify the duck bill drain is located at the bottom of the assembly.

  • Page 10: Spark Plugs

    6. If compression is still low, check for blown cylinder head gasket, valve leakage, or worn piston rings or cyl- inder (see Engine – Servicing Components). Spark Plugs  NOTE: The rear cargo tray must be removed for this procedure. CAUTION ATV-0052 Before removing a spark plug, be sure to clean the area...

  • Page 11: Front Differential - Transaxle Lubricant/Fluid

    7. Apply new engine oil to the new oil filter seal; then install the new oil filter onto the engine. Tighten securely. 8. Install the engine drain plug and new washer. Tighten to 7.2 ft-lb (9.8 N-m). Install the oil tank drain plug and new washer.

  • Page 12: Headlight - Taillight - Brake Light

    XX117 XX114 3. After the lubricant has been drained, install the drain 3. After the fluid has been drained, install the drain plug and tighten to 10-22 ft-lb (14-30 N-m). plug and tighten to 10-22 ft-lb (14-30 N-m). 4. Add SAE-approved 80W-90 hypoid gear lube into 4.
  • Page 13 REMOVING HEADLIGHT ASSEMBLY 1. Remove hood. 2. Remove the headlight retaining knob. XX072A INSTALLING HEADLIGHT ASSEMBLY 1. Install headlight bulb from rear of headlight assem- bly by turning clockwise. XX069A 3. Remove the wiring harness connectors. Remove the retainers on both sides of the headlight assembly that secure the headlight assembly.
  • Page 14 XX071 XX073 3. Install the wiring harness connectors. INSTALLING TAILLIGHT/BRAKE LIGHT 1. Install screws to the fascia. Connect the wiring har- ness connector. XX070B 4. Install the headlight retaining knob. XX073 CHECKING/ADJUSTING HEADLIGHT The headlights can be adjusted vertically. The geometric center of the HIGH beam light zone is to be used for ver- tical aiming.

  • Page 15: Hydraulic Brake System

    BLEEDING 3. Using the measurements obtained in step 2, make horizontal marks on the aiming surface directly in 1. To bleed hydraulic brake system, use the following front of each headlight. procedure: 4. Switch on the lights. Make sure the HIGH beam is A.

  • Page 16: Burnishing Brake Pads

    CHECKING/REPLACING PADS BRAKE DISC The clearance between the brake pads and brake discs is Using a micrometer, measure the thickness of the brake adjusted automatically as the brake pads wear. The only disc in the contact surface. If thickness is 0.125-in. or maintenance that is required is replacement of the brake less, the disc must be replaced.
  • Page 17 CHECKING Use the Drive Belt Gauge to identify any abnormal wear. Measure across the top of the V-belt (in multiple loca- tions) using a Vernier caliper. Do not squeeze the belt as doing so may produce an inaccurate measurement. The V-belt must be at least 38.4 mm (1.5 in.) at any point.

  • Page 18: 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. D. Ball joints not worn, cracked, or damaged. E.

  • Page 19: Body Panels

    CLEANING AND INSPECTING GRILLE Clean any dirt or debris from the grille webbing. This helps air flow to the radiator. INSTALLING GRILLE Place the grille into position and secure it using the exist- ing cap screws. Tighten all hardware to 60 in.-lb. Body Panels REMOVING REAR FASCIA XX085D...
  • Page 20 XX085A1 XX091 XX089 XX092 XX090 XX093 5. Remove the cap screws securing the rear lower 6. When removing right rear fenders, loosen the gas fender. When removing right side proceed to step 6. tank filler hose clamp behind the passenger seat. When removing left side, remove rear lower fender.
  • Page 21 XX091 XX084 INSTALLING REAR FENDERS 1. When installing right rear fender, install filler hose onto fender. Tighten hose clamp on gas tank filler hose. XX092 3. Install the rear upper fender. Secure with cap screws. XX083 2. Install the rear lower fender. Secure with cap screws. XX085A1 XX085B1 XX089...
  • Page 22 XX090 XX086 4. Install the rear upper front fender. Secure with cap REMOVING SIDE PANELS screws. To remove a side panel, remove the cap screws and push pins securing the side panel to the frame; then remove the panel. Front and/or rear fender removal will make side panel removal easier.
  • Page 23 XX107 XX100 2. Install rocker panel upward toward vehicle body. INSTALLING FRONT FENDERS Install push pins and cap screws securing the rocker panel to frame. 1. Align tabs on rear portion of fender into slots. REMOVING FRONT FENDERS 1. Remove fender flare fasteners. Remove fender flare being careful of the tabs at the rear of fender.

  • Page 24: Front Wheel Alignment

    XX476 XX463C To adjust the wheel alignment, use the following proce- dure:  NOTE: The tie rod threads are reverse thread. 1. Center the steering rack; then using an open-end wrench to hold the tie rod (A), loosen the outer jam nuts (B).

  • Page 25: Shift Cable

    XX235 XX236 2. Remove the screws securing the center console and INSTALLING the handle; then remove the shift knob. Remove the 1. Install both bushings into the shift lever; then secure console, handle, and knob. the shift lever to the frame and the bracket using the existing shoulder screw and new nut.

  • Page 26: Lcd Gauge

    XX238 XX240 4. Remove the cap screw and lock nut securing the shift 2. Once the proper adjustment is achieved, tighten the cable to the shift lever. Loosen the jam nut securing jam nut to 20 ft-lb (27 N-m). the shift cable to the shift bracket. Remove the shift ...
  • Page 27 VOR-502 XX259 2. Remove the screws (A) securing the skid plate; then 5. Remove all screws securing the rear cargo tray remove the skid plate. Remove the screws (B) and exhaust heat shield to the frame; then remove the nuts securing the rear hoop frame to the main frame. heat shield assembly rearward and out of the vehicle.

  • Page 28: Seats

    XX066 XX260 2. To install seat, slide the front of the seat frame (B) 3. Connect the oxygen sensor to the main harness; then into the seat retainers (A) and push down firmly on secure the sensor wires using two push-mount cable the rear of seat.
  • Page 29 XX103 XX096 3. To install seat, align the front of the seat frame to the 2. Remove the fasteners securing the door to hinge. approximate mounting location in front of gas tank and align the pins on the rear of the seat assembly with the eyelet.

  • Page 30: Deluxe Bimini Top

    3. Position the Deluxe Bimini Top into position and connect all four straps to the clamps at each corner of Deluxe Bimini Top the ROPS; then tighten all four straps at each corner of the ROPS . 4. Fasten the strap on the front portion of the ROPS . REMOVING/INSTALLING 1.

  • Page 31: Troubleshooting

    Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 32: Engine

    Engine This section has been organized into sub-sections which show a progression for the complete servicing of the engine. To service bottom-side components, the engine must be removed from the frame. To service top-side or left-side components, the engine does not have to be removed from the frame.
  • Page 33 XX269 XX259 11. Turn the set screw a 1/4 turn counterclockwise to 6. Remove all screws securing the rear cargo tray unlock the pin. Do not turn it more than1/4 turn. exhaust heat shield to the frame; then remove the heat shield assembly rearward and out of the vehicle.
  • Page 34 22. Disconnect the ground cable from the engine. XX271 XX284 17. Remove the oil hose from the throttle body boot; then loosen the clamp securing the boot from the 23. Using a suitable support jack supporting under the throttle body. engine/transaxle assembly, remove the two cap screws and limiter washers securing the front engine 18.

  • Page 35: Installing Engine

    VOR-515 XX245 31. Remove the two cap screws securing the rear of the 26. Carefully remove the engine/transaxle assembly out engine to the mid transaxle mount; then carefully the rear of the vehicle. remove the engine free from the cradle, mount, and 27.
  • Page 36 3. Thread in the existing cap screws to secure the rear 6. Install the belt around the pulley on the engine and of the engine to the mid transaxle mount; then the alternator; then apply tension to the belt using the tighten the driver-side cap screw to 65 ft-lb alternator.
  • Page 37 XX245 XX380 11. Secure the ground cable to the magneto cover using 15. Connect the main wiring harness to the TMAP sen- the existing screw. Tighten to 8 ft-lb (10.9 N-m). sor, the coils, and the injectors. Press the white push mounts into the injector rail.
  • Page 38 VOR-506 XX244 25. Secure the duct to the CVT inner cover using the NOTE: The screws used to secure the cover to the  existing clamp. Tighten securely. engine are p/n 1423-468 and the screws securing the cover to the transaxle are p/n 1423-220. 19.

  • Page 39: Servicing

    31. Install the shocks using the existing cap screws and nuts. Tighten to 65 ft-lb (88.4 N-m). Servicing 32. Align the manifold with the engine stud bolts. Push exhaust header into place so the engine exhaust studs go through the exhaust header. This engine sub-section has been organized to show a progression for servicing of the engine.
  • Page 40 SNO-279A NOTE: TDC on the compression stroke can be  VOR-518 found when the camshaft lobes for cylinder #3 (MAG 3. Remove plastic plug (A) from the MAG cover. side) are turned away from each other. NOTE: At this point, if the technician’s objective is ...
  • Page 41 YM-205 SNO-752 10. Using Flywheel Puller, remove the flywheel from the 8. Thread the MAG Cover Removal Cap Screw into the crankshaft. Account for the key in the crankshaft. timing mark hole; then carefully pull the MAG cover from the crankcase. Account for two dowel pins and a gasket.
  • Page 42 SNO-756 SNO-753 16. Remove the exhaust and intake camshafts from the  NOTE: The engine may have to be rotated for the engine. water pump gear to clear the counterbalancer. 13. Disconnect all hoses from the oil cooler; then remove the Allen-head screws securing the oil cooler assembly to the engine.
  • Page 43 YM-016A YM-020A 19. Tip the engine upside down; then remove the cap 22. Loosen the cap screws in decreasing numerical order screws securing the oil pan to the crankcase. Using a of the embossed numbers on the crankcase. Loosen soft hammer, gently tap around the oil pan until it each bolt 1/4 of a turn at a time.

  • Page 44: Servicing Components

    NOTE: The indicator mark (A) on the connecting 26. Straighten the locking tabs securing the cap screws  that secure the balancer shaft; then remove both cap rod cap will always point to the MAG end of the screws and both balancer weights. crankshaft.
  • Page 45 CHECKING CAMSHAFT LOBES CAUTION If any camshaft lobe is discolored or pitted or if the seating surface is worn, the camshaft must be replaced. 1. Measure the intake camshaft lobe heights (A): 34.350-34.450 mm (1.3523-1.3562 in.). <limit>: 33.650 mm (1.3248 in.). 2.
  • Page 46 CHECKING CAMSHAFT JOURNAL VALVES DIAMETER 1. Measure the camshaft journal diameter (A): 24.459-24.472 mm (0.9630-0.9635-in.). Replace if necessary. SNO-285 CAUTION SNO-726 If any valve is discolored or pitted or if the seating sur- 2. If the camshaft is within specification, the cylinder face is worn, the valve must be replaced.
  • Page 47 NOTE: Make a note of the position of each valve  lifter and valve pad so that they can be reinstalled in their original place. 4. To select the correct replacement shim for an out-of-specification clearance, note the three-digit number on the surface of the existing shim; then refer to the appropriate Tappet Shim Selection Table (Exhaust or Intake) in this sub-section and use this procedure:...
  • Page 48 SNO-660 SNO-684 NOTE: The numbers (A) stamped into the crank- 3. Put a piece of Plastigauge® on each crankshaft jour-  shaft web and the numbers on the connecting rods are nal. used to determine the replacement big end bearing sizes.
  • Page 49 NOTE: The numbers stamped into the crankshaft  CRANKSHAFT JOURNAL BEARING COLOR CODE web and the numbers stamped into the lower crank- case are used to determine the replacement crank- Black shaft journal bearing sizes. Brown Green Yellow Pink White PISTON ASSEMBLY SNO-686 SNO-862...
  • Page 50 Measuring Piston Skirt/Cylinder Clearance 1. Measure the cylinder bore using a gauge by taking side-to-side and front-to-back measurements of the cylinder. Then, find the average of the measure- ments. SNO-287 NOTE: If the existing rings will not be replaced with ...
  • Page 51 SNO-658A SNO-293A Measuring Piston Pin Bore Diameter NOTE: Be sure to install the piston rings so that the  manufacturer marks (A) face up. NOTE: It may be necessary to use Piston Pin Puller  to remove the piston pins. 2.

  • Page 52: Assembling

    2. If any journal is badly damaged or has wear that is not within specifications, the crankshaft must be replaced. Assembling  NOTE: The manufacturer recommends that new gaskets, seals, and O-rings be installed whenever assembling the engine. NOTE: For assembling purposes, use oil-dissolvable ...
  • Page 53 SNO-383A SNO-297 6. Apply engine oil onto the piston pin. Make sure the 9. Rotate the engine to the upside down position for “Y” mark (A) on the connecting rod faces to the installing the crankshaft. MAG side when the punch mark (B) on the piston is 10.
  • Page 54 SNO-440A 12. Align the hole (A) in the bearing with the pin (B) on the upper crankcase; then install the crankshaft. SNO-859 NOTE: Rotate the crankshaft one revolution to ver-  ify free movement. 15. Using Three Bond Sealant, apply a light film of seal- ant onto the sealing surfaces of the upper and lower SNO-857 engine cases.
  • Page 55 SNO-302 SNO-304 NOTE: Lubricate the threads and washers of cap NOTE: After the tightening sequence, rotate the   screws 1-8 with engine oil. Lubricate bolts 9-15, the crankshaft one revolution to verify free movement. threads of 19-24 and the mating surface with engine 21.
  • Page 56 NOTE: Clean the tapered portion of the crankshaft  and the flywheel. 26. With the key installed into the crankshaft, install the flywheel onto the crankshaft aligning with the key on the crankshaft until it is fully seated. Using a rubber hammer, tap the rotor onto the crankshaft.
  • Page 57 38. Install the camshafts with the hole (C) in cylinder #3 (cam facing up). When installing the timing chain, start with the intake camshaft and be sure to keep the timing chain as tight as possible on the intake side. Make sure the marks (D) on the timing chain sprock- ets are parallel with the edge of the cylinder head.
  • Page 58 NOTE: The “I” mark refers to the intake camshaft NOTE: Insert the timing chain tensioner rod little   caps and the “E” mark refers to the exhaust camshaft by little so that the circlip (A) comes into the groove in caps.
  • Page 59 VOR-518 45. Install the spark plugs. Tighten to 9.4 ft-lb (12.8 N-m). Install the ignition coils over the spark plugs making sure they are fully seated. Secure using existing cap screws. Tighten to 8 ft-lb (10.9 N-m). VOR-519...

  • Page 60: Assembly Schematic

    Assembly Schematic Torque Specification Tolerances Torque (ft-lb) Tolerance 0-15 ±20% 16-39 ±15% ±10% XX998cc_18_2...
  • Page 61 XX998cc_18_1...

  • Page 62: Troubleshooting

    Troubleshooting Problem: Engine Does Not Start (No Spark at Spark Plugs) Condition Remedy 1. Ground connections dirty — loose 1. Check all ground connections — clean and tight 2. Wiring harness shorting — disconnected 2. Repair — replace — connect wiring harness 3.

  • Page 63: Servicing Clutch Components

    Problem: Engine Overheats Condition Remedy 1. Coolant low — absent 1. Add coolant 2. Radiator obstructed 2. Remove obstructions 3. Drive system (primary sheave — secondary sheave — 3. Troubleshoot — adjust drive system track — drive belt) adjusted incorrectly — worn 4.
  • Page 64 5. Remove the cap screw with the Drive Clutch Bolt 2. Loosen the machine screws securing the cover. Tool and Drive Clutch Spanner Wrench by turning Remove every other cap screw and lock washer from counterclockwise securing the drive clutch assem- the cover;...
  • Page 65 1. With the cam arm pin properly positioned between the clutch towers, install the shoulder screw through the clutch and the cam arm. Secure using new lock nut. Tighten to 50 in.-lb (5.6 N-m). VOR-508 DRIVEN CLUTCH Disassembling 1. Place the movable sheave on the Driven Clutch VOR-510 Compressor Tool with the torque bracket facing up;...
  • Page 66 Cleaning and Inspecting 1. Using parts-cleaning solvent, wash grease, drive belt dust, and foreign matter off all components. CAUTION Do not use steel wool or a wire brush to clean driven components. A wire brush or steel wool will cause the sheaves to be gouged (thus, the drive belt may not slide between sheaves).
  • Page 67 SNO-547 VOR-506 NOTE: Before installing the drive clutch, be sure to  8. If the shock absorber was removed, install the rear wipe both the crankshaft taper and clutch mounting shock absorber and secure with the cap screws. taper clean using a clean towel. Tighten the upper cap screw to the recommended torque and the lower cap screw to the recommended 2.
  • Page 68 XX145 XX456 6. Slide the stationary off and verify only a 0.090” 9. While holding the Clutch Alignment Bar against the (2.29 mm) thickness shim is installed. If size is not a driven clutch as indicated in step 8, position the other 0.090”...
  • Page 69 SNO-778 11. Making sure the clutch cover gasket stays within the channel along the whole CVT cover housing, install the CVT cover starting from the rear of the vehicle. 12. Latch the clamps securing the CVT cover. 13. Connect the cooling duct to the CVT cover; install and tighten the clamp securing the cooling duct to the CVT cover.

  • Page 70: Fuel/Lubrication/Cooling

    Fuel/Lubrication/Cooling ! WARNING Whenever the gasline hoses are removed (other than for pressure testing), the battery must be disconnected to prevent inadvertent activation of the electric fuel pump. ! WARNING Whenever any maintenance or inspection is performed on the fuel system during which there may be fuel leak- XX084 age, there should be no welding, smoking, open flames, 3.

  • Page 71: Oil Pump

    3. Install the Oil Pressure Test Kit with a suitable fit- ting; then start the engine. While the engine is run- ning, there should be no leaks. 4. With a radiator fan on, increase the engine speed to 4800-4900 RPM. The oil pressure should be approx- imately 28-35 psi.

  • Page 72: Radiator

    NOTE: Debris in the engine compartment or 3. Turn the engine off and wait until engine is cool.  Add the recommended coolant/water mixture to fill packed between the cooling fins of the radiator can the coolant reservoir. reduce cooling capacity. Using a garden hose, wash the radiator to remove any debris preventing air flow.
  • Page 73 XX453 XX447A XX450A XX448 XX452 5. Disconnect the cooling fan electrical connectors and XX449 7. Remove the radiator/fan assembly from the vehicle note the location of any straps securing the electrical by lifting vertically. connectors. NOTE: If the radiator is to be replaced, transfer the ...

  • Page 74: Thermostat

    XX454 XX447A 4. Install the inner headlights to the headlight housing INSPECTING on both sides; then connect the electrical connectors 1. Inspect the thermostat for corrosion or spring dam- for the cooling fans; then secure back in place as age. noted during the removal procedure.

  • Page 75: Water Pump

    Water Pump ! WARNING When servicing the water pump, disconnect the battery cables to avoid injury. REMOVING 1. Drain the engine coolant. 2. Remove the outer CVT cover, the driven clutch, drive clutch and the belt. SNO-278 3. Remove the inner CVT cover to gain access to the DISASSEMBLING/ASSEMBLING water pump assembly.
  • Page 76 SNO-378A 4. Using a straight edge, make sure the impeller is flush SNO-374A with the damper. 4. Remove the rubber damper holder (A) and the rubber damper (B) from the impeller using a small flat-head screwdriver making sure not to damage the impeller shaft.

  • Page 77: Troubleshooting

    Troubleshooting Problem: Starting impaired Condition Remedy 1. Gas contaminated 1. Drain gas tank and fill with clean gas Problem: Idling or low speed impaired Condition Remedy 1. Gas contaminated 1. Drain gas tank and fill with clean gas 2. Throttle body dirty 2.

  • Page 78: Electrical System

    Electrical System TESTING ELECTRICAL COMPONENTS All electrical tests should be made using the Dealer Diag- nostic Service or the Fluke Model 77 Multimeter. The Dealer Diagnostic Service can return data for certain components which are identified at the beginning of their respective sub-section.

  • Page 79: Electronic Power Steering (Eps)

    1. When charging a battery in the vehicle, be sure the NOTE: The sealing strip should NOT be removed  ignition switch is in the OFF position. and NO fluid should be added. 2. Clean the battery terminals with a solution of baking 2.
  • Page 80 NOTE: If no active codes are present on the LCD or NOTE: If any codes are active and verified with the   verified through the Dealer Diagnostic Service and the Dealer Diagnostic Service, EPS replacement is not vehicle is experiencing steering-related issues, there always necessary.

  • Page 81: Ignition Switch

    TROUBLESHOOTING NOTE: If the meter shows no battery voltage, trou-  bleshoot the main 30-amp fuse, the battery, or the  NOTE: The EPS assembly is not serviceable and main wiring harness. must not be disassembled or EPS warranty will be 4.

  • Page 82: Accessory Receptacle/Connector

    2. Connect the red tester lead to the red/white wire; then connect the black tester lead to ground. 3. The meter must show battery voltage. NOTE: If the meter shows no battery voltage, trou-  bleshoot the battery, fuse, receptacle, connector, or the main wiring harness.
  • Page 83 NOTE: If the meter readings are OL or greater than  BRAKE LIGHT one ohm with the seat belt buckled, replace the buckle Component data can be retrieved using the Dealer Diag- switch assembly. If the resulting readings from step 5 nostic Service.

  • Page 84: Fan Motors

    2. Select the DC Volts position on the tester and observe the meter readings for each switch positions. Drive Select Switch WIRE COLOR LOCK Red tester lead to 12.0 DC Volts 12.0 DC Volts 12.0 DC Volts Orange Red tester lead to 11.5 DC Volts 0 DC Volts 11.5 DC Volts...

  • Page 85: Lights

    VOLTAGE 1. Locate the 4-wire connector for the front drive actua- tor above the differential; then connect the red meter lead to the orange wire using a MaxiClip. 2. Connect the black tester lead to the black wire using a MaxiClip;...

  • Page 86: Power Distribution Module (Pdm)

    XX336 MOD487 2. Connect the black meter lead to the black wire (B); LIGHT Switch then connect the red meter lead to the white/red wire (A). then turn the key switch to the on position and Open Open Open Open turn the light switch to the lights position.

  • Page 87: Efi Sensors/Components

    The fuses, relays, and a resistor are located in two sepa- rate power distribution modules under the battery access cover between the seats. If there is any type of electrical system failure, always check the fuses first. 6411-051 This vehicle uses automotive-style (see-through) fuses. The fuses can be visually inspected;...
  • Page 88 NOTE: The throttle body will not go through the  full verification process if the temperature is < 0° C (< 32° F). ! WARNING Short drives with this vehicle in freezing temperatures, or rapid hot/freezing cycles, may allow ice to form in the throttle body that can cause run issues.
  • Page 89 3. If the readings are not approximately as indicated, the sensor must be replaced. TEMPERATURE OHMS 40° C (104° F) 1128-1144 100° C (212° F) 151-159 4. Install the sensor and tighten securely; then connect the connector to the sensor. 5.
  • Page 90 Testing ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. AT THIS POINT  Prior to removing the electric fuel pump, the following check should be performed to determine that removal is necessary.
  • Page 91 Removing Fuel Pump Assembly 2. Move the float lever and check for free movement. The float assembly should return to the lower posi- 1. Remove the key from the ignition switch. tion without force. ! WARNING 3. Test the fuel level sensor by connecting a multimeter (A) to the fuel level sensor leads (B);...
  • Page 92 TILT SENSOR ! WARNING Incorrect installation of the tilt sensor could cause sud- den loss of engine power which could result in loss of vehicle control resulting in injury or death. CAUTION Do not drop the tilt sensor as shock can damage the internal mechanism.

  • Page 93: Starter Motor

    REMOVING 1. Disconnect the battery; then remove the rear skid plate and engine cover. CAUTION Always disconnect the negative battery cable from the battery first; then disconnect the positive cable. 2. Remove the nut (A) securing the positive cable to the starter;...

  • Page 94: Starter Relay

    NOTE: If a “click” is heard and more than one volt  is indicated by the multimeter, replace the starter relay. If no “click” is heard and the multimeter con- tinues to indicate battery voltage, proceed to step 4. 4. Disconnect the two-wire plug from the starter relay; then connect the red tester lead to the green wire and the black tester lead to the orange wire.
  • Page 95 XX332A XX367 2. Using a suitable multimeter, select the DC Voltage position; then connect the red tester lead to the posi- tive battery post and the black tester lead to the nega- tive battery post. Note the voltage with the engine not running.

  • Page 96: Electronic Control Module (Ecm)

    NOTE: The alternator/regulator is not a serviceable 3. Start the engine. The voltage should increase with the  engine running. Typically with the engine at idle it is part; therefore, it must be replaced as an assembly. around 14.0 DC volts with minimal electrical compo- Installing nents “on”...

  • Page 97: Gauge Diagnostic Menu

    DIAGNOSTIC MODES Error codes can be cleared by following the procedures located in the Gauge Diagnostic Menu sub-section in this Battery (BATTERY VOLTS) section. Gauge Diagnostic Menu DIGITAL GAUGE The digital gauge has a diagnostic menu that can be used to diagnose many of the DTCs displayed.
  • Page 98 Intake Air Temperature (AIR TEMP) Usage: Monitor throttle percentage to verify the follow- ing while the vehicle is running: 1. Throttle position sensor signal from throttle body. 2. Movement of throttle body via accelerator position sensor (limited movement when vehicle is not run- ning).
  • Page 99 Fuel Sensor (FUEL OHMS) Speedometer (MPH/KMH) XX350 XX351A Display: Fuel level signal from the fuel level sensor. Display: Vehicle speed signal (On the right screen on every diagnostic screen). DTC: C1400 DTC: P0500, P0503 Usage: Check output of the fuel level sensor.* Usage: Verify speedometer sensor signal from the fol- 1.

  • Page 100: Diagnostic Trouble Codes (Dtc)

    NOTE: Normal malfunction codes are cleared from  the LCD when the component is replaced or the mal- Diagnostic Trouble Codes function is corrected; however, intermittent codes (DTC) must be cleared as noted in the code chart. NOTE: Low system voltage, loose connections ...
  • Page 101 Display Fault Description Possible Cause Fault Recovery Method P0223 Throttle Position Sensor #2 Circuit High The throttle position sensor or its interconnect harness is shorted to Correct condition* battery power. P0261 Cylinder #1 Fuel Injector Circuit Low/SG Injector #1 or its interconnect harness is shorted to chassis ground. Correct condition** P0262 Cylinder #1 Fuel Injector Circuit High Injector #1 or its interconnect harness is shorted to battery power.
  • Page 102 Display Fault Description Possible Cause Fault Recovery Method P0693 Fan-Secondary Relay Control Circuit The secondary fan relay or its interconnect harness are shorted to Correct condition* Low/SG ground. P0694 Fan-Secondary Relay Control Circuit The secondary fan relay or its interconnect harness are shorted to Correct condition* battery power.

  • Page 103: Troubleshooting

    Troubleshooting Problem: Battery does not charge Condition Remedy 1. Battery wires/connections shorted — loose — open 1. Repair — replace — tighten battery wires/connections 2. Alternator belt loose — bad 2. Tighten — replace belt 3. Alternator/regulator failed 3. Replace alternator assembly 4.

  • Page 104: Drive And Brake Systems

    Drive and Brake Systems The following drive system components should be inspected periodically to ensure proper operation: A. Spline lateral movement (slop). B. Coupling cracked, damaged, or worn. C. Carrier bearing smooth rotation and bearing support tight. XX383 5. Remove the two cap screws that secure the steering GENERAL INFORMATION rack bracket to the subframe.
  • Page 105 XX386 XX390 9. Remove the upper differential mounting cap screw 12. Lower the subframe and differential while moving and nut. Account for the bushings. them forward slightly to release the rear of the sub- frame from the frame. XX387 10. Remove the two lower differential mounting cap XX392 screws and nuts.
  • Page 106 XX391 XX389 5. With the bushing in place, install the upper differen- 7. Using a new lock nut, install the two cap screws into tial mount cap screw using a new lock nut. Tighten to the rear of the subframe. Do not tighten. 35 ft-lb (47.6 N-m).

  • Page 107: Front Differential

    XX384 XX383 10. Using new “patch-lock” cap screws, secure the drive 5. Remove the two cap screws that secure the steering shaft coupler to the input of the differential. Tighten rack bracket to the subframe. evenly to 20 ft-lb (27.2 N-m). XX384 6.
  • Page 108 XX386 XX390 9. Remove the upper differential mounting cap screw 12. Lower the subframe and differential while moving it and nut. Account for the bushings. forward slightly to release the rear of the subframe from the frame. Removing the Actuator 1.
  • Page 109 XX402 XX427 3. Remove the three Torx T-30 cap screws that hold the 2. Make sure the shift shaft is properly lined up when actuator to the differential. Two are on the side (A) the actuator is fully seated. and one is behind the actuator (B). XX428 3.
  • Page 110 Disassembling Input Shaft 1. Remove the actuator as shown above. 2. Remove the four Torx T-40 cap screws. XX408 6. Inspect each component for wear or damage; replace if necessary. XX405 3. Remove the assembly. Account for a gasket. XX409 7.
  • Page 111 XX412 XX414 10. Inspect the seal. If the seal needs to be replaced, use 3. Place the small spring on the shaft. Using an awl or an appropriate seal removal and installation tool to similar tool to hold the slider shaft, install the 2 mm remove and replace.
  • Page 112 Disassembling Differential Assembly 1. Remove the input housing and actuator. 2. Using a Torx T-40 wrench, remove the cap screws securing the cover. XX419 7. Carefully pull the pinion gear and bearing out of the case. XX416 3. Using a plastic mallet, tap lightly to remove the dif- ferential cover.
  • Page 113 10. To replace, install the bearing onto the pinion shaft. XX423 3. Remove the locker shaft through the pinion gear CC882 housing area. 11. Place the pinion assembly in a bearing puller; then install the bearing using a press. XX424 4.
  • Page 114 5. Using a Torx T-40 wrench and green Loctite #270, 7. Place the spring under the cover and install the cover. install the eight cap screws that secure the cover to It will only go on in one orientation. Tighten the cap the case.
  • Page 115 XX391 XX389 2. With the bushing in place, install the upper differen- 4. Using a new lock nut, install the two cap screws into tial mount cap screw using a new lock nut. Tighten to the rear of the subframe. Do not tighten. 35 ft-lb (47.6 N-m).

  • Page 116: Drive Axles

    XX384 XX158A 7. Using new “patch-lock” cap screws, secure the drive Fig. 2 shaft coupler to the input of the differential. Tighten evenly to 20 ft-lb (27.2 N-m). XX159B 1. Lift the vehicle off the ground and remove the tire, castle nut lock and castle nut to release the axle.
  • Page 117 XX160A XX150A 6. Compress the inner CV joint and move it to the 4. Firmly grasp the inner cup and pull the axle from shown position. the transaxle. XX154A 7. With the cup still compressed, lower the swing XX151A 5. Support the swing arm by a hydraulic jack or simi- arm while simultaneously moving the axle out of lar tool.
  • Page 118 REMOVING FRONT DRIVE AXLE 1. Lift and support the vehicle with a support stand to allow access to the front suspension. 2. Remove the wheel. 3. Remove the lock plate and hub nut securing the hub. XX162A The picture below shows the locations of the lock on the set screw.
  • Page 119 XX186A XX197 3. Install the tie rod end using a new cap screw. Tighten CAUTION to 42 ft-lb (57.1 N-m). Support the knuckle when removing the cap screw to prevent damage. 7. Secure the upper A-arm up and out of the way. 8.
  • Page 120 XX184 CF636 6. Route the brakeline hose along the upper A-arm and 2. Use a suitable form of protection on the outside sur- secure it with the clips (B) and a cable tie (A). face of the CV joint, such as a strip of rubber or duct Tighten the clips to 6 ft-lb (8.2 N-m).

  • Page 121: Transaxle

    ASSEMBLING AXLES 1. Install the inner boot with the small clamp making sure the ends of the clamp are positioned correctly. NOTE: The boot is positioned correctly when the  small end of the boot seats down into the recessed groove.
  • Page 122 XX290 TA129 3. Wipe any oil or dirt from the seal area of the transaxle. 4. Using an appropriate seal installer and protector, install a new seal so it seats flush with the case (0.5 mm/0.02 in. deep). TA130 Pinion Plug NOTE: The transaxle does not need to be removed ...
  • Page 123 TA132 XX373 6. Remove the four Allen-head cap screws (two on REMOVING each side) that secure the subframe to the rear sec- 1. Place the vehicle securely on a support stand. tions of the frame. Remove the subframe from the vehicle.
  • Page 124 3. Remove and discard the lock nut securing the bell crank; then remove the bell crank from the shift shaft. A screwdriver or similar tool may be used to aid in removal. XX375 9. Remove the cap two cap screws (1) that secure the transaxle to the engine mount;...
  • Page 125 7. Clean any silicone residue from the case halves. DISASSEMBLING HALVES 1. Remove the shift shaft assembly, the detent, and the shift gear. XX301 5. Lift on the shift rail assembly to disengage the rail assembly from the case and rotate the rail away from the shift drum;...
  • Page 126 XX304 TA073A 9. Pry the pinion gear assembly to remove it from the CAUTION case. Account for the shim. When tapping the output shaft, make sure not to drop the shaft when it releases from the bearing to avoid gear damage.
  • Page 127 XX307 TA041 2. Inspect the gear teeth for nicks, cracks, chips, or 2. Inspect the rail for nicks, cracks, chips, or signs of signs of wear. If any are present, the gear must be wear. If any are present, the rail must be replaced. replaced.
  • Page 128 XX309 TA121 2. Inspect the cam groove for signs of wear. If present, 6. Rotate the cam clockwise so the tab of the spring replace the cam. installs into the shift drum groove. Install the washer to retain the spring. 3.
  • Page 129 TA048 TA051 3. Inspect the shaft gear teeth for nicks, cracks, chips, or signs of wear. If any are present, the shaft must be replaced. TA055 2. Inspect the gear teeth for nicks, cracks, chips, or signs of wear. If any are present, the gear must be replaced.
  • Page 130 H. Input Shaft J. Pinion Assembly 1. Inspect the bearings for free and smooth turning. If Inspect the teeth of the pinion gear and front output shaft. either bearing does not turn freely, it must be If any chipping, nicks, wear, or damage are observed, the replaced.
  • Page 131 TA086 TA077 5. Using an appropriate bearing driver, press the bear- 9. Install the small inner snap ring with shim. ing from the housing. BACKLASH AT THIS POINT  If the pinion shaft or gear were replaced or serviced, backlash must be checked. If not, proceed to ASSEM- BLING HALVES.
  • Page 132 NOTE: To determine the appropriate shim, proceed  to step 3. 3. Using an appropriate tool, lock the pinion gear in place. TA102 8. If backlash measurement is more than specified, remove the existing shim and install a thinner shim. NOTE: Continue to remove, measure, and install ...
  • Page 133 XX353 XX356 2. Install the intermediate shaft and idler shaft into the 4. Install the shift drum into the case; then engage the case only partially. Do not seat the shafts completely fork tabs into the grooves in the shift drum.Pinch the into the case at this time.
  • Page 134 7. Install the shift shaft gear onto the shift shaft with the timing marks facing up; then install into the case with the gear aligning with the shift drum gear. XX362  NOTE: It will be necessary to tap the cover onto the case using a rubber mallet.
  • Page 135 3. Using new lock nuts, secure the transaxle to the engine mount (1). Tighten to 65 ft-lb (88.4 N-m). Using blue Loctite #243, tighten the bracket to the engine mount (2). Tighten to 35 ft-lb (47.6 N-m). XX365 16. Using an appropriate seal installer, gently install a new plug over the pinion gear assembly so it fully seats past the chamfer —...

  • Page 136: Driveshaft/Carrier Bearing

    XX371 XX374 10. Install the cargo box tray, both rear wheels and axles, 7. Using new lock nuts, secure the subframe to the driver-side rear shock, inner clutch cover, both frame with the four Allen head cap screws (two on clutches and the outer clutch cover.
  • Page 137 XX432 XX435 5. Remove the boot clamps securing the driveshaft sec- 8. Remove the three cap screws that secure the differ- tions. Save the clamps for installation. ential to the frame. Account for all bushings and spacers. XX433 XX387 NOTE: Having the transmission in neutral will aid ...
  • Page 138 XX436 XX438 12. Remove the axle from the vehicle through the driver  NOTE: The cap screws that secure the front of the side of the cockpit. subframe to the frame can be removed to allow the front of the subframe to be lowered for more room. NOTE: At this point, no further disassembling is ...
  • Page 139 INSTALLING NOTE: The carrier bearing is intended to be a “slip  fit” assembly. It is very important that the surface is free of nicks and rust. It may be necessary to lightly scrub unpainted surfaces with emery cloth to ensure a smooth surface.

  • Page 140: Hydraulic Brake Caliper (Front Shown)

    Hydraulic Brake Caliper (Front Shown) ! WARNING The manufacturer recommends only authorized dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of control caus- ing severe injury or death. REMOVING/DISASSEMBLING XX435 1. Secure the vehicle on a support stand to elevate the 10.
  • Page 141 CLEANING AND INSPECTING 1. Clean all caliper components (except the brake pads) with DOT 4 brake fluid. Do not wipe dry. 2. Inspect the brake pads for damage and excessive wear.  NOTE: For measuring brake pads, see Periodic Maintenance/Tune-Up. 3.

  • Page 142: Master Cylinder Assembly

    Master Cylinder Assembly NOTE: The master cylinder is a non-serviceable  component; it must be replaced as an assembly. REMOVING 1. Slide a piece of flexible tubing over the front left brake caliper bleeder valve and direct the other end into a container.

  • Page 143: Disc Brake

    XX399 2. Install the pivot pin and secure with a the E-clip; then con- XX397 nect the spring. CAUTION 3. Using four new crush washers installed on both sides of Brake fluid is highly corrosive. Do not spill brake fluid the banjo fitting, secure the banjo bolts into the master cyl- inder.

  • Page 144: Troubleshooting

    Troubleshooting 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. Gear teeth broken 1. Replace gear(s) 2.

  • Page 145: Suspension

    1. Measure from the ground to the bottom of the frame tube in the locations shown behind the front lower Suspension A-arms. Measurement should be 14 in. (35.6 cm). The following suspension system components should be inspected periodically to ensure proper operation: A.

  • Page 146: Front A-Arms

    NOTE: For additional information, see the Perfor-  mance Manual. CAUTION Continuous high speed operation of this vehicle with excessive spring preload (suspension maintained at full extension) may result in CV boot damage. REMOVING 1. Secure the vehicle on a support stand to elevate the wheels and to release load on the suspension.
  • Page 147 5. Remove the cap screw and nut securing the tie rod end to the knuckle; then remove the tie rod end from the knuckle. XX188 9. Account for the bushing (B) and the seals (A) on the A-arm mount. XX185 6.
  • Page 148 XX193 XX191 3. Account for the bushing (B) and the seals (A) on the 3. Remove the bearing with a suitable press. A-arm mount. 4. Press a new bearing into place, and secure with the C-clip. NOTE: Remove the ball joint only if replacement is ...
  • Page 149 XX193 XX196 9. Using a new “patch-lock” cap screw, secure the 13. Install the knuckle on the lower ball joint using the shock to the lower A-arm. Tighten to 75 ft-lb existing cap screw and a new nut. Finger-tighten (102 N-m). only at this time.

  • Page 150: Rear Trailing Arms

    2. Support the trailing arm at full drop height with the shock installed. CAUTION Support the trailing arm to prevent it from going past the full drop position when the axle is in place. If the axle is in place and the trailing arm falls below full drop, damage to the axle will occur.
  • Page 151 8. Remove the cap screw securing the sway bar link to the trailing arm. XX204 6. The hub and bearing housing assembly may be removed. Doing so will prevent damage to the axle. XX208 9. Remove the cap screws securing the trailing arm to the frame.
  • Page 152 2. Press the spherical bearing into the trailing arm and secure it with a snap ring. NOTE: This bearing may already be installed in the  trailing arm. This bearing is not reusable. XX214 6. Install the shock absorber into the trailing arm mount and tighten to 65 lb-ft (88 N-m).
  • Page 153 XX217 XX220 10. Install the hub and axle nut. Apply red Loctite #271 13. When the correct distance is reached, tighten the jam to the axle nut and tighten to 250 lb-ft (339 N-m). nut to secure the rod end to the trailing arm. Note the Continue to tighten until the locking plate fits over orientation of the rod end.

  • Page 154: Front Sway Bar

    Front Sway Bar REMOVING NOTE: The vehicle does not need to be lifted off the  ground to service the sway bar. However, it does need to be on level ground so no tension is on the sway bar. 1. Remove the three cable ties and remove the deflector on both sides.

  • Page 155: Rear Sway Bar

    4. Rotate the sway bar down and under the chassis. 1. Remove and discard the cap screws and “patch-lock” nuts securing the sway bar to the sway bar link on both sides. XX252 5. Remove the sway bar through the lower A-arm. XX254 2.

  • Page 156: Wheels And Tires

    TIRE INFLATION PRESSURE 2. Install the bushings and bushing retainers on both sides. Use new “patch-lock” cap screws and tighten to 35 ft-lb Front and rear tire inflation pressure should be as specified (48 N-m). in the General Information/Foreword section. 3.

This manual is also suitable for:

2262-827

Table of Contents