Tracker 600 Service Manual
  1. Manuals
  2. Brands
  3. Tracker Manuals
  4. Offroad Vehicle
  5. 600
  6. Service manual

Tracker 600 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
SERVICE MANUAL
p/n: 2263-656
02/24
600

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 600 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Tracker 600

Summary of Contents for Tracker 600

  • Page 1 SERVICE MANUAL p/n: 2263-656 02/24...

  • Page 2: Table Of Contents

    T a b le o f C o n te n ts General Information/Foreword........2 Electrical System ............77 Specifications ............... 2 Battery .................77 Torque Specifications 3Torque Conversions (ft-lb/N-m)5 Electronic Power Steering (EPS) ........79 Gasoline — Oil — Lubricant ......... 5 Ignition Switch .............81 Preparation for Storage ..........

  • Page 3: General Information/Foreword

    NOTE: Specifications subject to change without notice. This Service Manual contains service, maintenance, and MISCELLANEOUS troubleshooting information for the 2024 600 ATV mod- Tire Size (Front) 25 x 8 – 12 els. The complete manual is designed to aid service per- 26 x 9 –...
  • Page 4 Torque Part Bolted to Part Torque Specifications ft-lb N-m Footwell — Right-Hand Rear Brake Reservoir in-lb Brake Clip Rear A-Arm  NOTE: Refer to the following torque value chart in-lb Brake Clip Front A-Arm whenever a torque value is called for in a procedure in-lb step.
  • Page 5 Torque Torque Part Bolted to Part Bolted to Part Part ft-lb N-m ft-lb N-m Body Plastic Body Plastic Throttle Body Boot Air Box Assembly in-lb Footwell — Right-Hand/Left-Hand Footwell — Duct, Intake Assembly Air Box Assembly Right-Hand/Left-Hand in-lb Footwell — Frame Duct, Engine-Intake/Frame Front Intake Duct Bracket...

  • Page 6: Gasoline - Oil - Lubricant

    RECOMMENDED GASOLINE Torque Conversions The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas, oxygenates are added to (ft-lb/N-m) the gasoline. Oxygenated gasolines containing up to 10% ethanol or 5% methanol are acceptable gasolines. When using ethanol-blended gasoline, it is not necessary ft-lb ft-lb ft-lb...

  • Page 7: Preparation For Storage

    The recommended transaxle/front differential (actuator on foot brake side) lubricant is Synthetic Transaxle Fluid Preparation after Storage with EP. This lubricant meets all the lubrication require- ments of the transaxle/front differential (actuator on foot brake side). Taking the ATV out of storage and correctly preparing it will ensure many hours of trouble-free riding.

  • Page 8: Periodic Maintenance/Tune-Up

    Periodic Maintenance/Tune-up Tighten all nuts, bolts, and cap screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, bolts, and cap screws are tightened to specifications (see Gen- eral Information/Foreword). It is advisable to lubricate certain components periodi- cally to ensure free movement.
  • Page 9 8. Remove the shop towel from the intake tube. Insert the filter the same way as removed making sure to push the filter all the way in toward the engine intake tube with the open end of the filter not visible at the front of the air box.

  • Page 10: Testing Engine Compression

    Testing Engine Compression 1. Remove the high tension lead from the spark plug. 2. Using compressed air, blow any debris from around the spark plug. ! WARNING Always wear safety glasses when using compressed air. ATV-0051 3. Remove the spark plug; then attach the high tension CAUTION lead to the plug and ground the plug on the cylinder Before removing a spark plug, be sure to clean the area...

  • Page 11: Engine/Transmission Oil - Filter

    2. Using a suitable brush, clean the carbon deposits 5. Apply oil to the new filter O-ring and check to make from the screen taking care not to damage the screen. sure it is positioned correctly; then install the new oil filter.

  • Page 12: Front Differential/Transaxle Lubricant

    Front Differential/Transaxle Lubricant FRONT DIFFERENTIAL CAUTION Any lubricant used in place of the recommended lubri- cant could cause serious front differential damage.  NOTE: Check location of the actuator on front dif- ferential to determine recommended lubricant. OHA019 When changing the lubricant on front differential (actua- 4.
  • Page 13 3. Drain the oil into a drain pan by removing the front differential drain plug (C) through the access hole (D) in the skid plate. Clean away any debris that may have accumulated onto the magnetic end of the plug. OHA022 2.

  • Page 14: Shift Lever/Shift Cable

    4. After the oil has been drained, use a pry bar without sharp edges to carefully lift up on the transaxle enough to align drain plug with access hole. Install the drain plug and tighten to 16 ft-lb (21.8 N-m). CAUTION Using a pry bar with sharp edges may result in transaxle case damage.

  • Page 15: Hydraulic Brake Systems

    Hydraulic Brake Systems CHECKING/BLEEDING The hydraulic brake systems have been filled and bled at the factory. To check and/or bleed a hydraulic brake sys- tem, use the following procedure: 1. With the master cylinder in a level position, check the fluid level in the reservoir. On the hand brake if the level in the reservoir is adequate, the sight glass will appear dark.

  • Page 16: Burnishing Brake Pads

    D. Repeat step B and C until the brake pedal is firm. 6. Carefully check the entire hydraulic brake system that all hose connections are tight, the bleed screws are tight, the protective caps are installed, and no leakage is present. CAUTION This hydraulic brake system is designed to use DOT 4 brake fluid only.

  • Page 17: Checking/Replacing V-Belt

    INSTALLING Checking/Replacing V-Belt 1. Place the belt (so the arrow is pointing toward the front of the vehicle) between the sheaves of the drive clutch. REMOVING 2. With the driven clutch sheaves fully apart, roll the belt over the stationary sheave. 1.

  • Page 18: Steering/Body/Controls

    Steering/Body/Controls  NOTE: The technician should use sound judgment and discretion when determining which components require removing to service a particular component. OHA052 The following steering components should be inspected periodically to ensure safe and proper operation: CLEANING AND INSPECTING A.
  • Page 19 1. Pull top of right-hand side panel (A) out to clear lip 4. To remove the right-hand footwell (C): Remove the of front fender and pull pegs from grommets (B). three screws and lock nuts (discard lock nuts) hold- ing the footwell to the frame. Remove the screw and nut securing the rear brake reservoir tank.

  • Page 20: Front Body Panels

    2. Position right-hand footwell (remove shifter knob if needed) and secure to frame with three screws and new lock nuts. Tighten to 5 ft-lb (6.8 N-m). Secure footwell to front and rear fenders with seven screws. Tighten to 5 ft-lb (6.8 N-m). Secure rear brake reser- voir tank to footwell with screw and nut with washer.

  • Page 21: Lcd Gauge

    INSTALLING 1. Position storage box (E) (see illustration OHA059) and secure with two shoulder screws. Tighten to 8 ft-lb (10.8 N-m). 2. Slide front fender panel rearward around steering post and secure to storage compartment box and frame with two trilobe machine screws below stor- age compartment box;...
  • Page 22 CAUTION Do not attempt to disassemble the EPS assembly as there are no serviceable components within the assem- bly and damage will occur voiding the EPS warranty. 10. Models without EPS Only: Remove two M10x1.25 cap screws and flange nuts to remove clamp (H) holding steering post (E).

  • Page 23: Handlebar Grip

    7. Inspect the handlebar tube for cracks, wear, or INSTALLING unusual bends. 1. Apply a liberal amount of Handlebar Grip Adhesive 8. Inspect the handlebar grips for damage or wear. to the inside of the new grip. INSTALLING 2. Slide the grip onto the handlebar until it is fully 1.

  • Page 24: Steering Knuckles

    Steering Knuckles REMOVING AND DISASSEMBLING 1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the wheel cap from the hub; then remove AF678D the cotter pin from the nut.
  • Page 25 XR166A MOD328 2. Position knuckle (A) on half shaft (B). Install the 5. Install the hub assembly onto the axle. upper (C) and lower (D) ball joints on the knuckle and secure with the two cap screws and nuts. Tighten to 45 ft-lb (61 N-m).

  • Page 26: Measuring/Adjusting Toe-Out

     NOTE: Ensure the inflation pressure is correct in the tires or inaccurate measurements can occur. 3. Place the ATV in a level position taking care not to push down or lift up on the front end; then turn the handlebar to the straight ahead position.

  • Page 27: Shift Lever

     NOTE: Prior to locking the jam nuts, make sure the ball joints are at the center of their normal range of motion and at the correct angle. XR213 733-559A Shift Lever REMOVING 1. Remove the seat, right-hand side panel, and right-hand footwell.

  • Page 28: Shift Cable

    Shift Cable REMOVING 1. Remove the seat, right-hand side panel, front fender panel and storage compartment box. Note routing of shift cable and cable tie locations. 2. Remove the cap screw and lock nut securing the shift cable to the shift lever. Loosen the jam nut securing the shift cable to the shift bracket.

  • Page 29: Front Bumper

    Muffler REMOVING 1. Using an appropriate tool, remove the springs secur- ing the muffler to the exhaust pipe. 2. Loosen two flange nuts securing exhaust pipe to engine and move exhaust pipe out of the way of muf- fler. OHA202 ...

  • Page 30: Headlights - Taillight

    INSTALLING 2. Remove the old H4 bulb by unlocking the spring; then insert the new bulb into headlight assembly and 1. Install muffler shield if needed. Account for spring lock the spring to secure the bulb. and flat washers and tighten screws to 10 ft-lb (13.6 N-m).
  • Page 31  NOTE: There should be an average operating load on the ATV when adjusting the headlight aim. 2. Measure the distance from the floor to the midpoint of each headlight. 3. Using the measurements obtained in step 2, make horizontal marks on the aiming surface directly in front of the headlights.

  • Page 32: 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 low 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 33: Engine/Transmission

    Engine/Transmission This section has been organized into sub-sections which show a progression of steps for the complete servicing of the engine and transmission. 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 34 OHA136 OHA148 11. Remove the nut securing the starter motor cable to 7. Disconnect taillight from wiring harness and cut any the motor. cable ties holding harness to upper frame. Note loca- tions of cable ties for assembly and move harness out 12.
  • Page 35  16. Use tape to cover and seal the intake opening. NOTE: Shims may have been used to properly locate the engine in the chassis. Note and mark the CAUTION location of any shims. Any objects or liquid entering the intake opening will 20.

  • Page 36: Servicing Engine

    Servicing Engine Specifications This sub-section is organized to show a thorough pro- CRANKSHAFT gression of steps to completely service engine compo- Connecting Rod (max.) 18.017 mm nents. For efficiency, however, it may be preferable to (small end inside diameter) Connecting Rod (big end side-to-side) 0.10-0.30 mm focus only on those components needing service.

  • Page 37: Disassembling Engine

    Disassembling Engine 1. With the engine secured to a suitable engine stand, drain oil, and remove oil filter, water pump, and hose (see Fuel/Lubrication/Cooling section and see Starter Motor sub-section in Electrical System section).  NOTE: Gear from water pump can be accessed when upper oil pan is disassembled.
  • Page 38 LYC039 LYC005 LYC005A LYC003 10. Remove three outer cylinder head screws. Then 8. To remove exhaust (A) and intake (B) cams, tilt one remove four cylinder head assembly nuts in a cam up to disengage chain from sprocket. Remove crisscross pattern to prevent damage. Account for tilted cam and then remove other cam.
  • Page 39 LYC007 LYC009  NOTE: At this point, if the technician’s objective is 14. Remove the two starter gears from the crankcase or magneto cover noting the direction of the gears for to service the valves, proceed to Servicing Compo- installation purposes; then remove the two starter nents —...
  • Page 40 LYC010 LYC037 17. Remove two screws holding oil pickup assembly (B) 20. With engine upside down, note the size and location and remove oil pickup assembly. and remove the 10 M6x35 screws (A), two M6x90 screws (C) and two M8 screws (B) that secure the lower crankcase to upper crankcase.
  • Page 41 22. Remove bearing halves from lower crankcase and mark location of each. LYC061  NOTE: The chain can be removed at this point. LYC060 26. Remove any carbon build up. Mark piston lobes as 23. Remove the two screws holding the connecting rod exhaust (A) and intake (B) for assembly purposes, cap and remove cap, accounting for bearing half.

  • Page 42: Servicing Engine Components

    LYC020 LYC002  28. Mark location of piston halve bearings for installa- NOTE: Always use new O-rings on three bolts used tion. to secure cover to cylinder head. CAM BRIDGE Cleaning and Inspecting 1. Clean cam bridge in parts-cleaning solvent and inspect for any damage.
  • Page 43 LYC040 LYC029 2. If damaged, the camshaft must be replaced. Measuring Valve Guide (Bore) VALVE ASSEMBLY 1. Insert a snap gauge halfway down into each valve guide bore; then remove the gauge and measure it Removing Valves with a micrometer. ...
  • Page 44 2. Inspect the spark plug hole for any damaged threads. 3. Place the cylinder head on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure-eight motion. Inspect the sealing surface for any indication of high spots.
  • Page 45 4. If a chain guide is damaged, it must be replaced. LYC026 Installing Cylinder Sleeve LYC041 1. Grease new O-ring and install on liner. 5. Inspect timing chain for any abnormality and tooth- ing. 2. Orientate sleeve in previously marked position and CYLINDER SLEEVE carefully install in top of upper crankcase.
  • Page 46 FI569 FI576A 3. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration. If any of the above conditions exist, replace the starter clutch assembly. LYC043 REPLACING STARTER GEAR BEARING 1. Support the starter clutch gear in a press making sure FI572 to support the hub around the entire circumference;...
  • Page 47 CRANKSHAFT Measuring Crankshaft (Runout) 1. Place the camshaft on a set of V blocks; then position the dial indicator contact point against the shaft and zero the indicator. FI580 INSPECTING STATOR COIL/MAGNETO COVER ASSEMBLY 1. Inspect the stator coil for burned or discolored wir- ing, broken or missing hold-down clips, or loose cap screws.
  • Page 48  NOTE: Bearing clearance may be confirmed using ® an indicator strip such as PLASTIGAUGE PISTON 1. Check proper seat of circlip. Disassembly 1. Using an awl, remove one piston-pin circlip. 2. Remove the piston pin. Mark pin as to MAG/PTO direction.
  • Page 49 CONNECTING ROD (CONROD) PISTON Assembling 1. Check small end for wear and discoloration. Measuring Small End 1. Install rings on piston per gap specifications. Orien- tate gaps as shown. 1. Insert a snap gauge into the upper conrod small end bore;...

  • Page 50: Assembling Engine

    2. Visually check that all fittings, sleeves and plugs are in place and accounted for in the crankcase halves (see Assembly Schematic at the end of this section). 3. The water pump can be assembled to the upper crankcase at this time. Do not install the hose at this time (see Fuel/Lubrication/Cooling section).
  • Page 51 5. Clean bearing surfaces, and install conrod and con- rod endcap bearings centered and with parting edges of conrod halves even with bearing edges. See Ser- vicing Engine Components — Connecting Rod (Conrod) for bearing selection. LYC047 8. Insert balancer shaft (B) and align sprocket marks to crankshaft sprocket mark.
  • Page 52 16. Clean sealant surface on bottom of lower crankcase and the upper oil pan. Apply liquid seal and two locating pins to crankcase bottom and position top oil pan (A) on crankcase. Secure with 13 top pan screws: three on inside and 10 on outer edges. Tighten to 88 in-lb (10 N-m).
  • Page 53 20. Wipe out any residual liquid seal in bore for oil pres- sure pump. Insert key in balancer shaft and then insert oil pressure pump. Install new O-ring on oil pressure pump cover. Secure oil pressure pump cover to crankcase with 3 screws. Tighten to 45 in-lb (5 N-m).
  • Page 54 28. Insert chain tensioner guide rail into chain case. Secure with ring seal and screw. Tighten to 80 in-lb (9 N-m). LYC006 34. Oil and replace lifter arms and rocker, matching the removal marking locations of each on both the cylin- der head and the rocker/lifter assembly.
  • Page 55 LYC055 LYC034 37. Oil camshaft bearing journals in cylinder head, and 40. Install O-ring in spark plug opening on cam bridge. place intake and exhaust camshafts in proper loca- Position cam bridge carefully over camshafts. Secure tions. Apply McLube® on cam lobes and axial bear- with seven bolts and carefully tighten by hand in pat- ing shoulder of both camshafts.
  • Page 56 LYC035 LYC036 46. Recheck top dead center (TDC) position by remov-  NOTE: Remove upper chain guard if attached to ing inspection cap from magneto cover. Align mag- cam bridge to make chain installation easier. neto rotor so timing mark is centered in inspection hole.
  • Page 57 51. Assemble O-rings onto two chain guide covers using O-ring grease. Place covers into housing bores and secure with four screws with Loctite applied. Tighten to 45 in-lb (5 N-m). LYC002 49. Secure cylinder head cover with three bolts and new O-rings.

  • Page 58: Assembly Schematic

    Assembly Schematic 8 N-m 18 N-m 70 in.-lb 13 ft-lb 10 N-m 88 in.-lb Steps Crisscross Tighten 15 N-m 10 N-m Crisscross Loctite + 11 ft-lb 88 in.-lb 9 N-m Steps 80 in.-lb 1. 10 N-m 88 in.-lb 10 N-m 2.
  • Page 59 Degrease cone surface 35 N-m 120 N-m 25 ft-lb 88 ft-lb 5.5 N-m 50 in.-lb Torque in Oil bolt head sequence* and threads; 10 N-m Steps 88 in.-lb Alternating 1. 10 N-m 88 in.-lb 2. 20 N-m 15 ft-lb 3. Another 60° turn 6 N-m 53 in.-lb 6 N-m...

  • Page 60: Installing Engine

    Installing Engine 1. Carefully place engine down into position using blocks to aid in locating proper height. Replace any shims used to properly locate engine in chassis in previously marked locations. 2. Install the right-side mounting plate and secure to engine with two bolts.
  • Page 61 OHA130 OHA139. 6. Reposition harness and secure to frame in previously 10. Assemble starter motor cable to the stud on starter noted position with cable ties. Connect taillight. and secure with nut. Tighten to 35 in-lb (4 N-m). 7. Connect coolant temperature sensor connector, and 11.
  • Page 62 15. Install the cyclone assembly’s (A) two crankcase vent hoses to engine and vent return hose to manifold intake. Secure with hose clamps. Tighten to 30 in-lb (3.4 N-m). OHA136  NOTE: Before installing the drive clutch, be sure to wipe clean both the crankshaft taper and clutch mounting taper using a clean towel.

  • Page 63: Troubleshooting Engine

    Troubleshooting Engine Problem: Engine does not start (no spark at spark plug) 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 64 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 65: Removing Drive And Driven Clutch

     NOTE: Before installing the clutch puller, apply oil to the threads of the puller and a small amount of Removing Drive and Driven grease to the tip of the puller. Clutch  NOTE: If only removing drive and driven clutch, remove seat, left-hand side panel and left-hand foot- well (see Steering/Body/Controls section).

  • Page 66: Servicing Clutch Components

    SPECIAL TOOLS 4. Using the Drive Clutch Retention Tool (resting on the driven clutch) to hold the drive clutch, tighten the cap A number of special tools must be available to the techni- screw and washer securing the cap screw to the cian when performing service procedures in this section.
  • Page 67 OHA145 OHA145 3. Remove the cover from the movable sheave; then 2. Install the mass blocks into the movable sheave. remove the six mass blocks taking note of how the  NOTE: Orient blocks as shown. mass blocks are orientated for installation purposes. ZR-432 ZR-432 Cleaning and Inspecting...
  • Page 68 VTA-080 ZR-438 3. Release the clutch compressor; then remove the snap ring, spring seat, spring guide, and the spring. VTA-084 6. Apply red Loctite #271 evenly to the threads of the new nut. ZR-439 4. Remove the movable sheave; then remove the screws securing the cam shoe to the sheave.
  • Page 69 3. Inspect the sheaves for any gouges, cracks, or other 3. Position the snap ring onto the spring seat; then using damage. the compressor tool, compress the spring until the snap ring can be installed into the groove in the post. 4.

  • Page 70: Fuel/Lubrication/Cooling

     3 If adjustment is needed, use driven clutch shims to NOTE: When indicated for use, each special tool adjust: will be identified by its specific name, as shown in the chart below, and capitalized. 0823-704 – 3 mm Description 0823-705 –...

  • Page 71: Throttle Cable Free-Play

    5. Remove the throttle cable (C) from the actuator arm 4. Connect the throttle cable to the throttle body and by loosening the outer jam nut securing the throttle adjust throttle cable free-play (see Throttle Cable cable to the throttle body; then route the cable out of Free-Play in this section);...

  • Page 72: Gas Tank

    Gas Tank ! 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. REMOVING 1. Remove the seat, right- and left-hand side panels, and left-hand footwell.

  • Page 73: Liquid Cooling System

    1. Connect the Tachometer to the engine or utilize the LCD gauge. 2. Connect the Oil Pressure Test Kit to the oil pressure test port according to manufacturer’s instructions. OHA013 3. Carefully rotate the radiator cap counterclockwise to release pressure; then remove the cap. OHA121 ...
  • Page 74 Installing 1. Position the fan/fan shroud assembly on the radiator; then secure with existing hardware. Reattach front screen. 2. Place the radiator with grommets and collars into position on the frame; then install the cap screws and nuts. Tighten to 12 ft-lb (16.3 N-m). 3.
  • Page 75 C. The thermostat should start to open at 160-187° F (71-86° C). D. If the thermostat does not open, it must be replaced. 3. Inspect all coolant hoses, connections, and clamps for deterioration, cracks, and wear.  NOTE: All coolant hoses and clamps should be replaced every four years or 4000 miles (6400 km).
  • Page 76 11. Loosen the lower hose clamp (B) and slide the clamp 4. Ensure cross pin is still in place and horizontal. Cor- away from the hose end approximately 2 in (5 cm); rect the angle of the pump shaft with a Torx T30 then remove hose from the water pump.

  • Page 77: Troubleshooting

    Troubleshooting NOTE: In all scenarios, perform a TPS/ISC reset first and check fuel pressure, which should be 3 bar or 43.5 psi. Problem: Starting impaired Condition Remedy 1. Battery discharged or defective 1. Test, charge, and/or replace battery 2. Gas contaminated 2.

  • Page 78: Electrical System

    Electrical System The electrical connections should be checked periodi- cally for proper function. TESTING ELECTRICAL COMPONENTS All electrical tests should be made using the Dealer Diag- nostic System or the Fluke Model 77 Multimeter. The Dealer Diagnostic System can return data for certain components which are identified at the beginning of their respective sub-section.
  • Page 79  Loss of battery charge may be caused by ambient tem- NOTE: The maintainer/charger will charge the bat- perature, ignition OFF current draw, corroded terminals, tery to 95% capacity at which time the Maintenance self discharge, frequent start/stops, and short engine run Charge Indicator (D) will illuminate and the main- times.

  • Page 80: Electronic Power Steering (Eps)

     NOTE: If no active codes are present on the LCD gauge or verified through the Dealer Diagnostic Sys- Electronic Power Steering tem and the vehicle is experiencing steering-related (EPS) issues, there may be a mechanical steering-related issue. In this case, the EPS is not the cause of the issue. Components that may contribute to this type of issue could be abnormal tire wear, bad wheel bearings, ball Component...
  • Page 81 Code Fault Description Fault Condition Possible Cause Fault Recovery Method C1315 Engine RPM Faulty Engine RPM CAN signal received by Broken main harness CAN wires or EPS will auto-recover when engine the EPS incorrect or missing defective ECM RPM signal returns to normal C1316 EEPROM Error EPS internal memory error has been Internal EPS condition...

  • Page 82: Ignition Switch

    Ignition Switch The ignition switch harness connects to the switch with a four-pin connector. To access the connector, remove the ignition switch nut. Switch will drop under front fender. Access switch and harness, and press the connector release tab. Pull the connector from the switch. ...

  • Page 83: Ignition Timing

    RESISTANCE CAUTION Accessory Receptacle/Connector Always disconnect the battery when performing resis- tance tests to avoid damaging the meter.  NOTE: For these tests, the meter selector should be  NOTE: This test procedure is for either the recepta- set to the OHMS position and the primary connector cle or the connector.
  • Page 84 RESISTANCE (Brake Light)  NOTE: If the meter shows more than 1 ohm of resis- tance, replace the left-side control assembly. 1. Set the meter selector to the OHMS position. RESISTANCE (Reverse Override) 2. Connect the red tester lead to one black wire; then connect the black tester lead to the other black wire.

  • Page 85: Fan Motor

    ! WARNING Care should be taken to keep clear of the fan blades.  NOTE: Fan motor resistance checks are not recom- mended. Resistance values change with the motor commutator position. Lights VOLTAGE (Headlights)  NOTE: Perform these tests on the main harness side of all four connectors.

  • Page 86: Power Distribution Module (Pdm)

    1. Set the meter selector to the OHMS position. Power Distribution Module 2. Connect the red tester lead to one spade end of the (PDM) fuse; then connect the black tester lead to the other spade end. 3. The meter must show less than 1 ohm resistance. If The fuses are located in the Power Distribution Module the meter reads open, replace the fuse.
  • Page 87 CRANKSHAFT POSITION (CKP)  NOTE: The ambient temperature of the engine and SENSOR in the intake and exhaust system must be at room temperature (approximately 68° F/20° C) when per- Resistance forming this test or an incorrect reading will occur. 1.
  • Page 88  1. Set the meter selector to the DC Voltage position. NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD 2. With appropriate needle adapters on the meter leads, gauge (see EFI Diagnostic System in the Electrical connect the red tester lead to the orange lead;...
  • Page 89 3. Test the fuel level sensor by connecting a meter to the fuel level sensor leads; then select OHMS. The meter should show 5 ohms at full fuel position and 95 ohms at empty fuel position.  NOTE: If readings are erratic, clean the resistor wiper and resistor with clean alcohol and retest.
  • Page 90 XR197A CD705D 2. Turn the ignition switch to the ON position. The meter THROTTLE POSITION SENSOR (TPS) should read battery voltage. If battery voltage is not indicated, check the 30-amp main and 10-amp ignition Component data can be retrieved using the Dealer fuses, wiring harness, or the ignition switch.

  • Page 91: Rpm Limiter

     NOTE: If the throttle body, ECM, TPS, or ISC are 3. Release the throttle lever, and wait an additional 10 seconds. replaced, the EFI system must be synchronized. Use the following procedure: 4. Turn the key to the OFF position and allow the gauge to shut off.

  • Page 92: Stator Coil

    Stator Coil VOLTAGE (AC Generator — No Load) Remove seat and right-hand side panel. The connector is a three-pin one in the harness coming from the AC gener- ator. OHA108 TESTING 1. Start engine and warm up to normal operating tem- perature;...

  • Page 93: Starter Relay

    OHA109 OHA112  INSTALLING NOTE: If the meter showed correct voltage but the starter motor did not operate or operated slowly, 1. Apply a small amount of grease to the O-ring seal on troubleshoot all starting system components before the starter motor; then install the starter motor into replacing the starter motor.

  • Page 94: Electronic Control Module (Ecm)

     NOTE: Make sure that the ignition switch is in the 4. Turn the key to the OFF position and allow the gauge to shut off. ON position, transmission in neutral, brake lock released, and the engine stop switch in the RUN posi- tion.
  • Page 95 Coolant (COOL) Diagnostic Mode Tachometer (tACH) Diagnostic Mode EFI 003 EFI009 Display: Engine coolant temperature as measured by the Display: Engine RPM ECT sensor. DTC: P0336, P0337, P0339 DTC: P0116, P0117, P0118, P0119 Usage: Verify engine speed signal from the following: Usage: Monitor coolant temperature to verify the following: 1.
  • Page 96 TPS (tPS) Diagnostic Mode Inlet Air Temperature (AIr) Diagnostic Mode EFI007 Display: % of TPS (0% closed, 95-100% WOT). EFI005 Display: Inlet air temperature in Fahrenheit or Celsius. DTC: P0121, P0122, P0123 DTC: P0112, P0113, P0114 Usage: Verify TPS signal and adjust throttle cable. Usage: Verify correct output of IAT sensor.
  • Page 97 Code List  NOTE: Normal malfunction codes are cleared from the LCD gauge when the component is replaced or the  NOTE: Each of the following numerical codes will malfunction is corrected; however, intermittent codes have a one-letter prefix of C, P, or U. A “C” prefix must be cleared as noted in the code chart.
  • Page 98 Fault Recovery Code Fault Description Possible Cause Method P0482 Fan-Secondary/Left Relay Control Circuit Secondary fan fuse has blown, the secondary fan relay has been Correct condition* Low/SG/Open removed or interconnect harness shorted to chassis ground P0483 Fan-Secondary/Left Relay Control Circuit Relay erratic or intermittent Correct condition* P0484...

  • Page 99: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace stator coil 4. ECM defective 4. Replace ECM 5. Pick-up coil defective 5.

  • Page 100: Drive System/Brake System

    Drive System/Brake System GENERAL INFORMATION The front differential is a 3.1:1 ratio. The die-cast aluminum housings have been assembled with thread-rolling screws (trilobular). When assembling with these screws, start the screws carefully into the housing; then use the following torque values: OHA129 2b.
  • Page 101 3. Inspect the brake disc for cracks or warping. 4. Inspect the hub for pits, cracks, loose studs, or spline wear. REPLACING WHEEL STUDS 1. Secure the hub in a suitable holding fixture. 2. Drive the damaged stud out of the hub; then place the new stud into the hub and thread on an appropriate nut.

  • Page 102: Drive Axles

    6. While holding the drive axle stationary, pull the top of the knuckle out and down until it is free of the drive axle. 7. Place a drain pan under the vehicle to contain any oil leakage. 8. Pull out sharply on the axle to dislodge the splines from the gear case.
  • Page 103 1. Using a clean towel, wipe away any oil or grease 3. To disengage the axle from the CV joint, sharply pull from the axle components. back on the axle; then slide the boot off of the axle. MOD513 MOD516 2.

  • Page 104: Front Drive Actuator

    3. Install the hubs (see Hub Assembly in this section). 4. Install the wheel; then using a crisscross pattern, tighten the wheel nuts in 20 ft-lb (27.2 N-m) increments to a final torque of 40 ft-lb (54.4 N-m) (steel wheel), 60 ft-lb (81.6 N-m) (aluminum wheel w/black nuts), or 80 ft-lb (108.8 N-m) (aluminum wheel w/chrome nuts).
  • Page 105 INSTALLING 1. Inspect actuator O-ring (A) for cuts and replace if needed. Ensure sealing surfaces on both pieces are clean and free of debris. Screw actuator into adapter seat. OHA163 OHA166A 2. Inspect adapter O-ring (A) for damage and ensure both machined surfaces are clean and free of debris.

  • Page 106: Front Differential

    Front Differential REMOVING 1. Remove the front wheels and front hubs (see Hub Assembly in this section). 2. Drain the oil into a drain pan by removing the drain plug through the access hole in the skid plate. Clean away any debris that may have accumulated onto the magnetic end of the plug.
  • Page 107 3. Remove the three 12 mm screws and one 8 mm screw holding the housing and pry off housing using the three dedicated pry notch locations. OHA171 OHA115 8. Remove the front differential from the vehicle. Front Differential Unit Disassembly and Assembly Front Differential Unit Disassembly 1.
  • Page 108 7. Split the front differential cover (A) from the case (B) by removing 10 screws and pry apart at the three dedicated pry notch locations (C), being careful not to damage sealing surfaces.  NOTE: Use two pry bars (or pry bar and screw- driver) together at each location to make splitting eas- ier.
  • Page 109 OHA182 OHA185 9. Pry the seal (A) off the case, being careful not to Servicing Front Differential damage sealing surface, and remove the retaining  ring (B). NOTE: Differential Carrier is serviced as an assem- bly. Front Differential Disassembly 1. Inspect bearing (A), and remove and replace if needed.
  • Page 110 OHA189 OHA193 OHA190 OHA194 2. Remove and discard the outboard seal (A). Then remove retaining ring (B). Drive Side Housing Assembly  NOTE: Use care to not damage mating surface during removal of outboard seal (A). 1. Press in bearing (C). Install retaining ring (B) and new outboard seal (A).
  • Page 111 Front Differential Unit Assembly 1. Place the ring gear (B) on the differential carrier (A) and install the differential carrier in gear case half. OHA181 OHA184 2. Secure the differential carrier in the gear case with retaining ring (B) and install a new seal (A). OHA179 5.
  • Page 112 8. Install the drive side cover housing and secure with the three 12 mm screws and one 8 mm screws. OHA178A 6. Install the drive clutch ring (B) on shaft and then slide shift fork (A) opening into groove on drive OHA171 clutch ring (B).

  • Page 113: Driveshaft

    INSTALLING DIFFERENTIAL 3. Install the upper differential mounting cap screw (A) with a new lock nut. Tighten to 45 ft-lb (61.2 N-m); 1. With the rubber boot (A), O-ring (B), and driveshaft then tighten the lower differential mounting cap bumper (C) set in place, place the differential assem- screws to 16 ft-lb (21.8 N-m).

  • Page 114: Transaxle

    3. Slide the driveshaft forward and out. ASSEMBLY 1. Lightly coat the splines of the driveshaft with molyb- denum grease; then couple the driveshaft to the tran- saxle by gently sliding the driveshaft toward the rear of the vehicle. Verify the O-rings and boot are intact for the coupler.
  • Page 115 TA117 OHA130 3. Put vehicle on support stand and remove tires, hubs CAUTION (see Hub Assembly section) and drive axles (see Drive Axles section). Do not drive the awl too far or bearing damage will occur. 4. Remove clutch covers, rear duct and clutch (see 2.
  • Page 116 OHA112A OHA142A 8. On right side, remove shift lever cable bracket, Dis- connect the gear position switch connector and speed sensor connector. OHA112B 10. Remove front differential mounting bolts and discard lock nuts, and move front differential and driveshaft forward to disengage driveshaft from transaxle. OHA100 Account for boots and seals.
  • Page 117 11. Remove rear mount bolt and lift transaxle out of the vehicle. OHA119 SEPARATING TRANSAXLE HALVES OHA124 6. Remove the 19 mm detent near the gear position 1. With the transaxle on a bench, drain the fluid into a switch. Account for the spring and O-ring. suitable pan.
  • Page 118 OHA126 TA139 3. With the upper half of the transaxle flat on the bench, remove the eight screws securing the pinion gear assembly. OHA127 8. Clean any silicone residue from the case halves.  NOTE: Edges of halves may be sharp. Wear protec- tive gloves and use caution when touching these areas.
  • Page 119 NKL022 NKL025 CAUTION There is a ball bearing below the pinion seal. Use cau- tion not to damage the bearing while removing the seal.  NOTE: The pinion seal must be replaced if removed. 6. Remove the inner snap ring on the front output shaft; then using a mallet, tap the front output shaft down into the case half.
  • Page 120 NKL003 NKL012 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 121 NKL043 NKL007 3. Push shift shaft (C) through case and remove. 3. Inspect the shaft gear teeth for nicks, cracks, chips, Inspect and replace O-ring if needed. or signs of wear. If any are present, the shaft must be replaced. F.
  • Page 122 NKL015 NKL018 3. Then pull the cam off the shift drum. Inspect the cam 6. Reassemble parts in reverse order of disassembly, groove for signs of wear. If present, replace the cam. from step 5 to step 1. CAUTION When installing snap ring, the cam is under a spring load.
  • Page 123 NKL031 NKL029 3. Remove retaining ring and then remove gear (C), 5. Remove retaining ring and remove engagement dog account for bearing and washer. Inspect the gear (F) Inspect the dogs for nicks, cracks, chips, or signs teeth for nicks, cracks, chips, or signs of wear. If any of wear.
  • Page 124 NKL038 NKL010 8. Assemble in reverse order of steps 7 to 1. 3. Inspect the shaft gear teeth for nicks, cracks, chips, or signs of wear. If any are present, the shaft must be H. Input Shaft replaced. 1. Inspect the bearings for free and smooth turning. If either bearing does not turn freely, it must be replaced.
  • Page 125  NOTE: To determine the appropriate shim, start with the thickest shim and install the snap ring. If the snap ring will not fit in the groove, remove the shim and install the next size smaller shim. Continue until the snap ring can be installed. 2.
  • Page 126 9. Tape the splined portion of the pinion shaft to protect the seal; then using an appropriate seal installer, install the front output seal so it seats fully past the chamfer of the case. OHA128A 2. Apply a coat of Loctite 5699 to the case; then ensur- ing the shift shaft (O-ring lightly coated with grease) and shift rail are correctly seated, install the cover.
  • Page 127 2. Place the transaxle into position on the rear mounting studs and secure using new lock nuts. Tighten to 25 ft-lb (34 N-m). OHA100 OHA119 3. Move driveshaft rearward to engage with transaxle. Account for boots and seals. Install lower differential mounting cap screw (B) with a new lock nut but do not tighten at this time.

  • Page 128: Hand Brake Lever/Master Cylinder Assembly

    OHA117 AF637D 2. Place an absorbent towel around the connection to absorb brake fluid. Remove the banjo-fitting from the master cylinder. Account for two crush washers and a banjo-fitting bolt. OHA116 8. Install clutch, rear duct and clutch covers (see Engine/Transmission section).

  • Page 129: Hydraulic Brake Caliper

    4. Inspect the banjo-fitting for cracks and deterioration ! WARNING and the condition of the fittings (threaded and com- Never let brake fluid contact the eyes. Damage to the pression). eyes will occur. Always wear appropriate protective INSTALLING safety goggles and latex gloves when handling brake fluid.
  • Page 130 2. Inspect the brake pads for damage and excessive wear.  NOTE: For measuring brake pads, see Periodic Maintenance/Tune-up. 3. Inspect the brake caliper housings for scoring in the piston bores, chipped seal ring grooves, or signs of corrosion or discoloration. 4.
  • Page 131 5. Making sure brake fluid does not contact the brake pads, compress the caliper holder toward the caliper and install the inner brake pad; then install the outer pad. CAUTION If brake pads become contaminated with brake fluid, they must be thoroughly cleaned with brake cleaning solvent or replaced with new pads.

  • Page 132: Troubleshooting Drive System

    Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shafts serration worn — broken 1. Replace shaft Problem: Power not transmitted from engine to either front wheel Condition Remedy 1. Secondary drive — driven gear teeth broken 1.

  • Page 133: Suspension

    CAUTION Suspension Additional support stands are necessary to support the rear axle when the shock absorbers are removed or damage may occur. The following suspension system components should be 3. Remove the two cap screws and nut securing each inspected periodically to ensure proper operation: rear shock absorber to the frame and upper A-arm.

  • Page 134: Front A-Arms

    8. Tap the ball joints out of the knuckle; then remove the knuckle. Front A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.
  • Page 135 2. Install the upper (F) and lower (G) A-arm assemblies into the frame mounts and secure with the cap screws. Only finger-tighten at this time. 3. Reattach brake hose clamp to upper A-arm (F).  NOTE: Do not allow the brake caliper to hang from the cable/hose.

  • Page 136: Rear A-Arms

    Rear A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the wheels ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Remove the wheel. XR211 9. Secure the hub assembly (B) to the shaft/axle with 3.
  • Page 137 INSTALLING 1. Install the A-arm assemblies into the frame and secure with the cap screws and new lock nuts. Only finger-tighten at this time. OHA096 7. Remove the cap screws and lock nuts securing the knuckle (E) to the upper (F) and lower (G) A-arms. Discard the lock nuts.

  • Page 138: Wheels And Tires

    8. Place bolting plate (A) on hub. Wheels and Tires TIRE SIZE ! WARNING Use only approved tires when replacing tires. Failure to do so could result in unstable ATV operation. The ATV is equipped with low-pressure tubeless tires of the size and type listed in General Information.

  • Page 139: Troubleshooting

     2. Inspect the tires for damage, wear, or punctures. NOTE: If pulling is noted, measure the circumfer- ence of the front and rear tires on the pulling side. ! WARNING Compare the measurements with the tires on the opposite side. If pulling is noted during braking only, Do not operate the ATV if tire damage exists.
  • Page 140 OFFROADM ©2024 TRACKER OFF ROAD ™ ® Trademarks of White River Marine Group, LLC ™...

This manual is also suitable for:

2263-656

Table of Contents