Table Of Contents - Tracker Off-Road XTR1000 Service Manual

General Information/Foreword ......................................... 2
Specifications ............................................................... 2
Torque Specifications ................................................... 3
Torque Conversions (ft-lb/N-m) .................................... 4
Drive Belt Break-In Procedure ...................................... 4
Gasoline - Oil - Lubricant ......................................... 4
Preparation for Storage ................................................ 5
Preparation after Storage ............................................. 6
Periodic Maintenance/Tune-Up ........................................ 7
Air Filter ........................................................................ 7
Spark Arrester .............................................................. 8
Valve/Tappet Clearance ............................................... 8
Testing Engine Compression........................................ 8
Spark Plugs .................................................................. 9
Engine Oil - Filter ....................................................... 9
Front Differential - Transaxle Lubricant/Fluid ........... 10
Headlight - Taillight - Brake Light........................... 11
Hydraulic Brake System ............................................. 14
Burnishing Brake Pads ............................................... 15
Replacing V-Belt ......................................................... 15
Steering/Body/Controls................................................... 17
Hood/Rear Cargo Tray/Grille ...................................... 17
Body Panels ............................................................... 18
Front Wheel Alignment ............................................... 23
Shift Lever .................................................................. 23
Shift Cable .................................................................. 24
LCD Gauge................................................................. 25
Exhaust System.......................................................... 25
Seats .......................................................................... 27
Deluxe Bimini Top ...................................................... 29
Front Bumper.............................................................. 29
Rear Bumper .............................................................. 29
Troubleshooting .......................................................... 30
Engine ............................................................................... 31
Removing Engine ....................................................... 31
Installing Engine ......................................................... 34
Servicing ..................................................................... 38
Disassembling ............................................................ 38
Servicing Components ............................................... 43
Assembling ................................................................. 51
Assembly Schematic .................................................. 59
Troubleshooting .......................................................... 61
Servicing Clutch Components .................................... 62
Fuel/Lubrication/Cooling................................................. 69
Gas Tank .................................................................... 69
Oil Pump ..................................................................... 70

Table of Contents

Fuel Pump ...................................................................70
Fuel/Vent Hoses..........................................................70
Liquid Cooling System ................................................70
Radiator.......................................................................71
Thermostat ..................................................................73
Fans ............................................................................73
Water Pump ................................................................74
Troubleshooting ..........................................................76
Electrical System..............................................................77
Battery .........................................................................77
Electronic Power Steering (EPS) ................................78
Ignition Switch .............................................................80
Ignition Coils................................................................80
Accessory Receptacle/Connector ...............................81
Switches ......................................................................81
Fan Motors ..................................................................83
Front Drive Actuator ....................................................83
Lights...........................................................................84
Power Distribution Module (PDM) ...............................85
EFI Sensors/Components ...........................................86
Starter Motor ...............................................................92
Starter Relay ...............................................................93
Alternator/Regulator/ Rectifier/Stator ..........................93
Electronic Control Module (ECM)................................95
Gauge Diagnostic Menu..............................................96
Diagnostic Trouble Codes (DTC) ................................99
Troubleshooting ........................................................102
Drive and Brake Systems ..............................................103
Front Drive Coupler ...................................................103
Front Differential........................................................106
Drive Axles ................................................................115
Transaxle ..................................................................120
Driveshaft/Carrier Bearing.........................................135
Hydraulic Brake Caliper (Front Shown).....................139
Master Cylinder Assembly.........................................141
Disc Brake .................................................................142
Troubleshooting ........................................................143
Suspension .....................................................................144
Shock Absorbers .......................................................144
Front A-Arms .............................................................145
Rear Trailing Arms ....................................................149
Front Sway Bar .........................................................153
Rear Sway Bar ..........................................................154
Wheels and Tires ......................................................155
Troubleshooting ........................................................155
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