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Tracker LX4 2020 Repair And Service Manual

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REPAIR AND SERVICE MANUAL
699326- A
Issued August 2019

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Summary of Contents for Tracker LX4 2020

  • Page 1 REPAIR AND SERVICE MANUAL 699326- A Issued August 2019...
  • Page 3 699326 Repair and Service Manual...
  • Page 4 Repair and Service Manual 699326...
  • Page 5 Certain replacement parts can be used independently and/or in combination with other accessories to modify this vehi- cle to permit it to operate at or in excess of 20 mph. When a vehicle is modified in anyway by the Distributor, Dealer, or customer to operate at or in excess of 20mph on public streets or roads.
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  • Page 14 Notes: Repair and Service Manual...
  • Page 15 Notes: Repair and Service Manual...
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  • Page 17 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Lift Flap on Access Panel Part A Part B Serial Number Labels Part D Part C 699326 Repair and Service Manual...
  • Page 18 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To decrease the risk of causing an electrical arc, which could result in a battery explosion, turn off all electrical loads from the batteries before removing any heavy gauge battery wires.
  • Page 19 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The canopy does not provide pro- tection from roll over or falling objects. Rack Ball Rack Ball The windshield provides only minimal protection Joint Joint from tree limbs or flying objects.
  • Page 20 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ALL TORQUE FIGURES ARE IN FT. LBS. (Nm) Unless otherwise noted in text, tighten all hardware in accordance with this chart. This chart specifies 'lubricated' torque figures.
  • Page 21 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699326 Repair and Service Manual...
  • Page 22 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699326...
  • Page 23 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Always use correct service proce- dures. Never do any type of ser- NOTICES, CAUTIONS, WARNINGS, DANGERS vice procedure before you read and understand all notices, cau- tions, warnings and dangers in this manual.
  • Page 24 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Open flame or sparks can cause an explosion. Keep all flammable materials away from the batteries. Explosive hydrogen gas is created during the charge cycle of the batteries.
  • Page 25 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. When you lift the vehicle, put the jacks and jack stands at the areas indicated (Figure 2). Black from White from Main Contactor Control Harness Yellow from...
  • Page 26 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. View from Underside of Vehicle Repair and Service Manual 699326...
  • Page 27 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699326 Repair and Service Manual...
  • Page 28 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699326...
  • Page 29 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Drill out rivet NOTICE: Hardware that is removed must always be Pop Rivet head only installed in its original position unless otherwise specified.
  • Page 30 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: The instrument panel (1) may be removed without removing the cowl (5) or may be removed as part of the cowl (Figure 4). To decrease the risk of injury due to lack of vehicle information, the cor- rect safety label must be on the...
  • Page 31 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: The cowl can be removed along with the front fenders. To decrease the risk of personal injury, disconnect negative (-) bat- tery cable before servicing vehicle.
  • Page 32 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle FOR VEHICLES MANUFACTURED AFTER JUNE 02, 2019 Front of Vehicle FOR VEHICLES MANUFACTURED BEFORE JUNE 02, 2019 Repair and Service Manual 699326...
  • Page 33 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle 699326 Repair and Service Manual...
  • Page 34 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Repair and Service Manual 699326...
  • Page 35 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle 699326 Repair and Service Manual...
  • Page 36 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Bottom, Rear View of Frame Repair and Service Manual 699326...
  • Page 37 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Vehicle Frame 699326 Repair and Service Manual...
  • Page 38 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Place a piece of sheet metal between the battery case and the rivets to be removed as a secondary precaution. Extreme care must be used when drilling out rivets located near the battery.
  • Page 39 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. All painting must be done in an area with adequate ventilation to safely disperse harmful vapors. Wear eye protection and respirator, following manu- facturer’s instructions, to protect from over-spray and airborne mist.
  • Page 40 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699326...
  • Page 41 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To decrease the risk of tire explosion, add small amounts of air to the tire at intervals to seat the tire beads. Over inflation of small tires can occur in a few seconds.
  • Page 42 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To decrease the risk of compo- nent damage, do not tighten lug nuts to more than 85 ft. lbs. (115 Nm) torque.
  • Page 43 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699326 Repair and Service Manual...
  • Page 44 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699326...
  • Page 45 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Part of Frame Intermediate Shaft with U-Joints Wave Washer Bearing Outer Snap Ring Rack and Pinion Inner Snap Ring Thrust Washer King Pin Tube Rack Ball Joint Rack Extension...
  • Page 46 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Do not use more than three (3) pumps of grease in any grease fit- NOTICE: Hardware that is removed must always be ting at any one time.
  • Page 47 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Hub Replace- ment NOTICE: Once hub is placed onto spindle and before outer wheel bearing is installed, fill the area between the inner and outer wheel bearings 1/2 - 3/4 full with grease.
  • Page 48 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Rear Front of Vehicle 0" (0 mm) 1/8" (3 mm) Front NOTICE: Use a wrench on the center, flat section of the tie rod to hold the tie rod while loosening the jam nut.
  • Page 49 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Part of Frame Part of Frame Front of Vehicle *NOTE: Tie Rod Not Shown for Clarity 699326 Repair and Service Manual...
  • Page 50 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. and pinion unit to the steering column from pulling apart due to the weight of the steering system. NOTICE: The intermediate shaft is assembled with the universal joints set 90°...
  • Page 51 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wheel Alignment NOTICE: After the springs are replaced, the axle will need to be aligned to the frame. Unless the axle has been replaced, wheel alignment will not be affected;...
  • Page 52 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. A - Install this side of seal into housing Wheel Alignment B - Lubricate lip of seal Wheel Bearing Adjustment Front of Vehicle Hub Replacement Wheel Bearing...
  • Page 53 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Wheel Bearing Adjustment 699326 Repair and Service Manual...
  • Page 54 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Flat Section Repair and Service Manual 699326...
  • Page 55 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Measure exposed thread length. Use measured length to position new ball joint at same location. Flat section towards end identifies end with left hand threads After replacing or servicing steering components, verify that a 1/8"...
  • Page 56 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: Use the measurement taken earlier to the position the rod end on the tie rod tube. Grooves Rack Ball Joint Replacement After replacing or servicing steering Wheel Alignment components, always verify that a...
  • Page 57 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. ment The spindle bearings are designed to be used “dry”. Lubrication attracts dirt and will ruin the bear- ings. Do not apply grease to the spindle bearings. Lip of Seal Front of Vehicle...
  • Page 58 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Wheel Alignment NOTICE: The rack and pinion gears are not service- able items. If they are found to be damaged or excessively worn, a new rack and pinion unit must Rack and Pinion Unit be installed.
  • Page 59 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. After replacing or servicing steering components, always verify that a 1/8" gap exists between large hex of rack extension and rack and pinion unit when steer- ing is turned fully to the right forcing passenger spindle arm against front axle.
  • Page 60 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle NOTICE: To maintain correct orientation when replacing the steering wheel, turn the wheels straight ahead. Rack Passenger Side To decrease the risk of damage to Ball Spindle Arm...
  • Page 61 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Steering Wheel Replacement 699326 Repair and Service Manual...
  • Page 62 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Steering Wheel Replace- ment Install with arch Small up as shown Retaining Ring Steering Shaft Bearing Groove NOTICE: Apply grease to the splines. Repair and Service Manual 699326...
  • Page 63 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699326 Repair and Service Manual...
  • Page 64 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699326...
  • Page 65 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Speed Sensor To decrease the risk of electrical shock, the BL- wire must be removed before discharging the controller by shorting the B+ and B- terminals of the controller with a large screw- driver.
  • Page 66 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To decrease the risk of electrical shock, the BL- wire must be removed before discharging the controller by shorting the B+ and B- terminals of the controller with a large screw- driver.
  • Page 67 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Do not hold vehicle on a hill using the accelerator, which is known as a “stalled” condition. Leaving motor in a stalled condi- tion for more than 3-4 seconds can cause perma- nent damage to the motor.
  • Page 68 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Rear Axle Repair and Service Manual 69932669...
  • Page 69 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Disconnect the negative (BL-) battery cable with an insulated wrench before attempting to dis- connect wires from the motor (see safety procedures in SAFETY section). Motor O-ring 699326...
  • Page 70 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: If continuity is not observed between ter- minals; an open motor field condition may exist. Disassemble the motor to visually confirm. NOTICE: If continuity is observed between the case and terminals;...
  • Page 71 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699326 Repair and Service Manual...
  • Page 72 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699326...
  • Page 73 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. otherwise damaged in any way. Refer to all repair work to qualified personnel. The charger is not for use by children. Use charger only on 72 volt bat- tery systems.
  • Page 74 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: Routing the DC cord through the steering wheel when charging the batteries, serves as a good reminder to store the cord out of the way when charging is complete.
  • Page 75 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699326 Repair and Service Manual...
  • Page 76 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699326...
  • Page 77 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. wrench from shorting out a battery, which could result in an explosion. NOTICE: Always observe the following warnings when working on or near batteries: To decrease the risk of battery explosion that could result in severe personal injury or death,...
  • Page 78 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Do not overfill batteries. The charging cycle will expel electro- lyte and result in component damage. Vent Cap Gas Vent Expansion Space Vent...
  • Page 79 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: The watering device should only be used if the electrolyte level is less than 1/2" (13 mm) above top of plates. To decrease the risk of battery damage, be sure that all battery caps are tightly installed.
  • Page 80 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Disconnect battery charger, con- troller and other electronic devices since they will contrib- ute to the premature discharge of To decrease the risk of battery batteries.
  • Page 81 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: In some portable chargers, there will be a rattle present in the body of the charger DC plug. This rattle is caused by an internal magnet con- tained within the charger plug.
  • Page 82 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: Do not perform a hydrometer test on a bat- tery that has just been watered. The battery must go through at least one charge and discharge cycle in order to permit the water to adequately mix with the electrolyte.
  • Page 83 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Electrolyte Temperature ° F ° C 71.1 +.032 +.030 65.6 +.028 +.026 60.0 +.024 EXAMPLE #1: +.022 Electrolyte Temperature 54.4 +.020 Above 80°F (27°C) +.018...
  • Page 84 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699326...
  • Page 85 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual...
  • Page 86 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Bare wires may cause a short cir- Bare wires may cause a short cir- cuit. cuit. Hydrogen gas formed during bat- Hydrogen gas formed during bat- tery charging is explosive and tery charging is explosive and...
  • Page 87 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use of incorrect fuse rating can damage electrical components. NOTICE: Following procedure is applicable for vehi- cles with halogen headlights. NOTICE: Following procedure is applicable for vehi- cles with LED headlights.
  • Page 88 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Front of Vehicle Repair and Service Manual...
  • Page 89 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To prevent possible injury or death resulting from a battery explosion, use an insulated wrench and remove the BL- wire from the battery to disconnect electrical power to vehicle.
  • Page 90 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Press to activate switch Repair and Service Manual...
  • Page 91 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Parking Brake Pedal Torsion Springs Push Nut Identification Hole Hinge Pin Service Brake Pedal Pedal Latch Spacer Kick Off Catch Bracket Cap Screw Brake Pedal Pivot Bolt Screw...
  • Page 92 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Pedal Latch Never manually adjust the brakes at the star wheel. Doing so will cause permanent damage to the adjuster assembly and result in a gradual loss of brakes.
  • Page 93 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Remove Both Drums Don't Disturb Brake Mechanism Adjust Visual External Visually Check Correct Inspection Visually Inspect Replace Condition of: Includes Drums Brake Cables: Frayed...
  • Page 94 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Disassemble Adjuster Tries Brake, to Move Star Wheel? Install Wheel and Tire, Clean, Lube. Star Wheel Rotates? Check Tire Pressure. Replace Free Movement of Torque Lug Nuts.
  • Page 95 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 699326 Repair and Service Manual...

  • Page 96: Maintenance And Repairs

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Pedal Bumper Adjustment Adjust- ing Brake Pedal Free Travel 1/4" - 3/8" (6 - 9.5 mm) Diameter Drill or Bolt Must Pass Adjust At Bumper If Needed Through Gap MAINTENANCE AND REPAIRS...
  • Page 97 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Use a 'bathroom' scale to confirm the latching force required to engage and latch the parking brake. Brake Part of Pedal Frame Loosen...
  • Page 98 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Hinge Torsion Springs Push Not To Exceed 1/8" To prevent serious injury or (3 mm) death from the use of worn park Front brake components, do not Either...
  • Page 99 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: To ensure correct braking performance, all maintenance, inspections and procedures must be performed as indicated in the PERIODIC SERVICE SCHEDULE section.
  • Page 100 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. A backing plate assembly that shows any indication of galling or gouging is not repairable and PASSENGER Forward must be replaced with a new SIDE Drum Rotation wheel brake assembly.
  • Page 101 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 7/8" - 1 1/8" (2.2 - 2.9 cm) Jam Nut Spherical Nut All brake tests must be done in a safe location with regard for the safety of all personnel.
  • Page 102 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Clevis Pin Loose Front of Vehicle NOTICE: Do not apply the brake when removing the nut as the shoes may not fully retract, preventing removal of the brake drum.
  • Page 103 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Do not back off nut to install cot- Be sure that the adjusting screw ter pin. is threaded into the star wheel nut until only 1 - 2 threads are exposed.
  • Page 104 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: When brake shoes are replaced, adjusters and springs must also be replaced. Do one side at a time, using the other side for reference. Repair and Service Manual 699326...
  • Page 105 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. TOP PULL ADJUSTER ASSEMBLY 699326 Repair and Service Manual...
  • Page 106 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Brake Drum Removal and Instal- lation Adjusting Brake Pedal Free Travel Repair and Service Manual 699326...
  • Page 107 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: The brake cables and equalizer are only serviceable as a complete assembly. Adjusting Brake Pedal Free Travel Cotter Clevis Compensator Spherical Assembly...
  • Page 108 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Park Brake Kick-Off Cam Removal, Replacement and Installation Pedal Latch Arm .03" (.76 mm) max gap after adjustment of cam Cam must be against latch arm at this point with no gap.
  • Page 109 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 1/4" - 3/8" (6 - 9.5 mm) diameter drill or bolt must pass Adjust at bumper if needed. through tap. Parking Brake Kick-Off Cam Removal, Replacement and Installation Accelerator...
  • Page 110 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699326...
  • Page 111 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The rear axle is a precision assembly, and therefore any repair or replacement of parts must be done with extreme care in a clean environment.
  • Page 112 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Bearing Separator To decrease the risk of seal dam- age, lightly coat the axle shaft with bearing grease and support the shaft during installation.
  • Page 113 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: Tighten the axle nut to torque value speci- fied below. Continue to tighten until the slot in the nut aligns with the cotter pin hole. Thin Thrust Inner Snap Washer...
  • Page 114 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699326...
  • Page 115 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To reduce the possibility of personal injury, follow the lifting procedure. Place wheel chocks in front of and behind the front wheels and check the stability of the vehicle on the jack stands before starting any repair procedure.
  • Page 116 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. NOTICE: If the springs are to be replaced and the rear axle is not to be removed, it is important to remove and replace one spring at a time.
  • Page 117 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle 699328 Repair and Service Manual...
  • Page 118 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. To reduce the possibility of personal injury, follow the lifting procedure of this manual (See LIFTING THE VEHICLE on page 8). Place wheel chocks in front and behind the front wheels and check the stability of the vehicle on the jack stands before starting any repair procedure.
  • Page 119 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699328 Repair and Service Manual...
  • Page 120 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699328...
  • Page 121 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. The canopy does not provide pro- tection from roll over or falling objects. The windshield does not provide protection from tree limbs or flying objects.
  • Page 122 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Front of Vehicle Vehicle Shown for Reference 18 19 DETAIL D (Rear) Front of Vehicle DETAIL A DETAIL B (Outside Tubing On Sun Top) Front of Vehicle DETAIL C...
  • Page 123 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Take care not to warp wind- shield when raising and low- ering the top section of windshield. 699326 Repair and Service Manual...
  • Page 124 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Strut DETAIL D Windshield Front of Vehicle DETAIL A DETAIL B Windshield Front of Vehicle Vehicle Shown for Strut Reference DETAIL C Strut Lower Latch...
  • Page 125 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699326 Repair and Service Manual...
  • Page 126 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699326...
  • Page 127 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. LEFT RIGHT DOWN Plug the Curtis handheld program- mer into Curtis programmer port only. If plugged into the wrong port, voltage from other interface circuits may result in permanent damage to the programmer.
  • Page 128 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 699326...
  • Page 129 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 699326 Repair and Service Manual...
  • Page 130 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 699326...
  • Page 131 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 699326 Repair and Service Manual...
  • Page 132 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Example: Battery Undervoltage (code 23). In the Fault menu of the 1311 programmer, the words Undervoltage Cutback will be displayed; the real-time battery voltage is displayed in the Monitor menu (”Keyswitch Voltage”).
  • Page 133 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 699326 Repair and Service Manual...
  • Page 134 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 699326...
  • Page 135 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 699326 Repair and Service Manual...
  • Page 136 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 699326...
  • Page 137 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 699326 Repair and Service Manual...
  • Page 138 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 699326...
  • Page 139 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 699326 Repair and Service Manual...
  • Page 140 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 699326...
  • Page 141 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699326 Repair and Service Manual...
  • Page 142 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699326...
  • Page 143 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 699326 Repair and Service Manual...
  • Page 144 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 699326...
  • Page 145 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: 699326 Repair and Service Manual...
  • Page 146 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual 699326...
  • Page 147 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 699326 Repair and Service Manual...
  • Page 148 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual 699326...
  • Page 149 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 699326 Repair and Service Manual...

  • Page 150: Scheduled Maintenance Chart

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. SCHEDULED MAINTENANCE CHART Repair and Service Manual 699326...
  • Page 151 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Repair and Service Manual...

  • Page 152: Save These Important Safety Instructions

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 8VHU·V *XLGH SAVE THESE IMPORTANT INFORMATIONS IMPORTANTES DE SÉCURITÉ SAFETY INSTRUCTIONS Ce manuel contient des instructions importantes This manual contains important safety and operating concernant la sécurité...

  • Page 153: Maintenance

    Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. 4. Optional Charger Single-LED Display (internal or external) LED Colour Indication (following “Power-On Self Test”) Green Solid: Charging complete. Charger in Maintenance Mode. Flashing: Short: <80% Charge.
  • Page 154 Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers. Notes: Repair and Service Manual...
  • Page 155 NOTICE: Read the following operational warnings before driving the vehicle: NOTICE: Read the following maintenance information and warnings before servicing or repairing the vehicle:...

  • Page 156: Manufacturer Information

    MANUFACTURER INFORMATION Textron Specialized Vehicles Inc. 1451 Marvin Griffin Road Augusta, GA, USA 30909-3852 Dealer: 800-296-4804 Consumer: 877-394-6772 www.trackeroffroad.com Owner’s Manuals and Repair Manuals are available from the manufacturer. Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of the manufacturer.