Servicing; Disassembling - Tracker Off-Road XTR1000 Service Manual

31. Install the shocks using the existing cap screws and
nuts. Tighten to 65 ft-lb (88.4 N-m).
32. Align the manifold with the engine stud bolts. Push
exhaust header into place so the engine exhaust studs
go through the exhaust header.
33. Starting in the middle, secure using the existing nuts.
Tighten to 16 ft-lb (21.8 N-m).
XX260
34. Connect the oxygen sensor to the main harness; then
secure the sensor wires using two push-mount cable
ties.
35. Install the rear cargo tray heat shield assembly to the
frame using the existing screws. Tighten securely.
36. Position the muffler with the manifold and secure
using the existing springs; then secure the muffler to
the transaxle bracket using the existing cap screws,
washers, and nuts. Tighten to 16 ft-lb (21.8 N-m).
XX259
37. Install the rear hoop frame and secure using the
existing screws and new nuts. Tighten to 35 ft-lb
(47.6 N-m).
38. Install the skid plate and the rear cargo tray.
39. Install the cooling system and the oil system.
38

Servicing

This engine sub-section has been organized to show a
progression for servicing of the engine. For consistency
purposes, this sub-section shows a complete and thor-
ough progression; however, for efficiency it may be pref-
erable to disassemble only those components needing to
be addressed. Also, some components may vary from
model to model. The technician should use discretion and
sound judgment.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this engine
section.
NOTE: When indicated for use, each special tool

will be identified by its specific name, as shown in the
chart below, and capitalized.
Description
Ball Hone
Flywheel Puller Kit
Piston Pin Puller
V Blocks
Drive Clutch Spanner Wrench
Ring Compressor
MAG Cover Removal Cap Screw

Disassembling

1. With the engine secured to a suitable engine stand,
remove the cap screws securing the ignition coils to
the valve cover. Remove the coils and the spark
plugs.
VOR-519
2. Remove the four Allen-head screws and gaskets
securing the valve head cover to the cylinder head;
then remove the cover. Account for the gasket.
p/n
Common Tool
0744-083
Common Tool
Common Tool
0644-136
Common Tool
2623-100