operator’s manual · go at a speed which is proper for the terrain, visibility con-ditions, and...

8/20

800SX/800SX LE

p/n: 2263-009

OPERATOR’S MANUAL

This vehicle can be hazardous to operate.A collision or rollover can occur quickly, even during what you think are routinemaneuvers such as driving or turning on flat terrain, driving on hills, or crossingobstacles, if you fail to take proper precautions. For your safety, understand and fol-low all the warnings contained in this Operator’s Manual and on the labels on thisvehicle.Keep this Operator’s Manual with this vehicle at all times. If you lose your manual,contact the manufacturer for a free replacement. The labels should be considered per-manent parts of the vehicle. If a label comes off or becomes hard to read, contact anauthorized dealer for a free replacement. Contact the manufacturer for proper regis-tration information.FAILURE TO FOLLOW THE WARNINGS CONTAINED IN THIS MANUALCAN RESULT IN SERIOUS INJURY OR DEATH.Particularly important information is distinguished in this manual by the followingnotations:

FREE ROV SAFETY TRAININGFree training is available for Recreational Off-Highway Vehicle (ROV) operators and passen-gers from the Recreational Off-Highway Vehicle Association (ROHVA). The manufacturerrecommends that you complete this course before you first use your new ROV.This online course takes approximately two hours to complete and presents you with a certifi-cate of accomplishment as soon as you complete the course. The course does not have to becompleted all at one time. It will remember where you left off and bring you back to that pointwhen you return.ALWAYS USE COMMON SENSE WHEN OPERATING THIS VEHICLE.Visit www.ROHVA.org to start your training.

California Proposition 65

!The Safety Alert Symbol means ATTENTION!BE ALERT! YOUR SAFETY IS INVOLVED.

! WARNING WARNING indicates a hazardous situationwhich, if not avoided, could result in death orserious injury.

CAUTION CAUTION, without the safety alert symbol, isused to address practices not related to per-sonal injury.

NOTE: A NOTE provides key information to make pro-cedures easier or more clear.

! WARNINGThe Engine Exhaust from this product contains chemicalsknown to the State of California to cause cancer, birthdefects or other reproductive harm.

www.ROHVA.org

ForewordCongratulations and thank you for pur-chasing a Tracker Off RoadTM vehicle.Built with American engineering andmanufacturing know-how, it is designedto provide superior ride, comfort, utility,and dependable service.This Operator’s Manual is furnished toensure that the operator is aware of safeoperating procedures. It also includesinformation about the general care andmaintenance of this vehicle. Carefully read the following pages. Ifyou have any questions regarding thisvehicle, contact an authorized dealer forassistance. Remember, only authorizeddealers have the knowledge and facilitiesto provide you with the best service pos-sible.

• Become familiar with all local andstate/provincial laws governing ROVoperation,

• Respect your vehicle,• Respect the environment, and• Respect private property and do not

trespass.The manufacturer advises you to strictlyfollow the recommended maintenanceprogram as outlined. This preventivemaintenance program is designed toensure that all critical components on thisvehicle are thoroughly inspected at vari-ous intervals.All information in this manual is basedon the latest product data and specifica-tions available at the time of printing.The manufacturer reserves the right tomake product changes and improvementswhich may affect illustrations or explana-tions without notice.You have chosen a quality productdesigned and manufactured to givedependable service. Be sure, as the owner/operator of this vehicle, to become thor-oughly familiar with its basic operation,maintenance, and storage procedures.Read and understand the entire Operator’sManual before operating this vehicle toensure safe and proper use. Always oper-ate the vehicle within your level of skilland current terrain conditions.

Division II of this manual covers opera-tor-related maintenance, operatinginstructions, and storage instructions. Ifmajor repair or service is ever required,contact an authorized dealer for profes-sional service.At the time of publication, all informa-tion and illustrations in this manual weretechnically correct. Some illustrationsused in this manual are used for claritypurposes only and are not designed todepict actual conditions. Because themanufacturer constantly refines andimproves its products, no retroactiveobligation is incurred.

Operation of this vehicle is restricted topeople 16 years of age and older whopossess a valid driver’s license. Passen-gers must be able to place both feet flaton the floor while keeping their backagainst the seat and holding on to anavailable handhold.

Protect Your Sport

Parts and Accessories

When in need of replacement parts, oil,or accessories for this vehicle, be sureto use only GENUINE PARTS, OIL,AND ACCESSORIES. Only genuineparts, oil, and accessories are engi-neered to meet the standards andrequirements of this vehicle. For acomplete list of accessories, refer tothe current ROV Accessory Catalog.To aid in service and maintenance pro-cedures on this vehicle, a Service Man-ual and an Illustrated Parts Manual areavailable through an authorized dealer.

1

Table of ContentsForeword ................................................1Parts and Accessories ..........................1Division I — SafetySafety Alert .............................................4Hangtags .............................................5-6Important Safety Information................7Warning Labels ...................................8-9Location of Parts and Controls ..........10Warnings .........................................11-19Division II — Operation/MaintenanceSpecifications ......................................20Vehicle Operation ...........................21-26General Information........................27-40

Control Locations and Functions ......27Doors and Shoulder Bars..................29Cargo Box Tie-Downs .......................29Power Steering (if equipped) ............31LCD Information Gauge (Digital)............32Diagnostic Trouble Codes ......................34Load Capacity Ratings Chart ............37Trailering and Towing ........................38Transporting ......................................38Gas — Oil — Lubricant .....................39Engine Break-In ................................40Burnishing Brake Pads .....................40

General Maintenance......................41-62Maintenance Schedule .....................42Liquid Cooling System ......................43Shock Absorbers...............................44General Lubrication...........................45

Hydraulic Brake.................................47Fuel Hoses ........................................48Protective Rubber Boots ...................48Rear Knuckle Grease Zerks ..............49Battery ...............................................49Spark Plug(s).....................................52CVT Air Inlet ......................................52Primary Air Filter/Safety Filter/Clean-out

Valve ..............................................53Tires ..................................................55Wheels ..............................................56Muffler/Spark Arrester .......................56Light Bulb Replacement ....................57Checking/Adjusting Headlight Aim ....59Fuses.................................................60Electrical Output Terminals................60Storage Compartments/Tools............61Seat Belts ..........................................62Doors.................................................62ROPS ................................................62

Preparation for Storage.......................63Preparation after Storage....................63Warranty Procedure/Owner

Responsibility...................................64U.S. EPA Emission Control Statement/

Warranty Coverage — ROV (U.S. Only) .65California Emission Control Statement/

Warranty Coverage — OHRV (U.S. Only) ..................................................66

Maintenance Record............................67Change of Address, Ownership, or

Warranty Transfer ............................69Identification Numbers Record...........71

p/n: 2263-009

2

Division I — SafetyThis vehicle is not a toy and can be hazardous to operate.

• Always go slowly and be extra careful when operating on unfamiliar terrain. Always bealert to changing terrain conditions when operating this vehicle.

• Never operate on excessively rough, slippery, or loose terrain.• Always follow proper procedures for turning as described in this manual. Practice turn-

ing at slow speeds before attempting to turn at faster speeds. Do not turn at excessivespeed.

• Always have the vehicle checked by an authorized dealer if it has been involved in anaccident.

• Never operate on hills too steep for your abilities. Practice on smaller hills beforeattempting larger hills.

• Always follow proper procedures for climbing hills as described in this manual. Checkthe terrain carefully before you start up any hill. Never climb hills with slippery or loosesurfaces. Never depress the accelerator suddenly or make gear changes while moving.Never go over the top of any hill at high speed.

• Always follow proper procedures for going down hills and for braking on hills asdescribed in this manual. Check the terrain carefully before you start down any hill.Never go down a hill at high speed. Avoid going down a hill at an angle which wouldcause the vehicle to lean sharply to one side. Go straight down the hill where possible.

• Always be careful when you decide to climb or descend a hill and never turn on a hill.Drive straight up or down inclines and not across them. If you must cross the side of ahill, drive slowly and stop or turn downhill if you feel the vehicle may tip over.

• Always use proper procedures if you stall or roll backward when climbing a hill. Toavoid stalling, maintain a steady speed when climbing a hill. If you stall or roll back-wards, follow the special procedure for braking described in this manual.

• Always check for obstacles before operating in a new area. Never attempt to operateover large obstacles, such as large rocks or fallen trees. Always follow proper proce-dures when operating over obstacles as described in this manual.

• Always be careful of skidding or sliding. On slippery surfaces, such as ice, go slowlyand be very cautious in order to reduce the chance of skidding or sliding out of control.

• Never operate this vehicle in fast-flowing water or in water deeper than the floorboard.Remember that wet brakes may have reduced stopping capability. Test your brakes afterleaving water. If necessary, apply them lightly several times to let friction dry out thepads.

• Always be sure there are no obstacles or people behind you when you operate inreverse. When it is safe to proceed in reverse, go slowly. Avoid turning at sharp anglesin reverse.

• Always use the size and type tires specified in this manual. Always maintain proper tirepressure as described in this manual.

• Never improperly install or improperly use accessories on this vehicle.• Never exceed the stated load capacity for this vehicle. Cargo should be properly distrib-

uted and securely attached. Reduce speed and follow instructions in this manual for car-rying cargo or pulling a trailer and allow greater distance for braking.

• Operation of this vehicle is restricted to people 16 years of age and older who possess avalid driver’s license. Passengers must be able to place both feet flat on the floor whilekeeping their back against the back of the seat and holding on to an available handhold.

! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. 3

Safety AlertYou should be aware that THIS VEHI-CLE IS NOT A TOY AND CAN BEHAZARDOUS TO OPERATE. Thisvehicle handles differently from othervehicles, including motorcycles and cars.A collision or rollover can occur quickly,even during what you think are routinemaneuvers, such as turning, driving onhills, and going over obstacles, if you failto take proper precautions.

TO AVOID SERIOUS INJURY OR DEATH:

* Always read the Operator’s Manualcarefully and follow the operatingprocedures described. Pay specialattention to the warnings contained inthe manual and on all labels.

* Always wear the seat belt when oper-ating or riding in this vehicle.

* Always follow these age recommen-dations:• Operation of this vehicle is restricted

to people 16 years of age and olderwho possess a valid driver’s license.Passengers must be able to place bothfeet flat on the floor while keepingtheir back against the back of the seatand holding on to the handhold.

* Never carry a passenger in the cargobox of this vehicle.

* Never operate this vehicle on a publicroad, even a dirt or gravel one,because you may not be able to avoidcolliding with other vehicles.

* Always wear an approved helmet andprotective gear.

* Never consume alcohol or drugsbefore or while operating this vehi-cle.

* Never operate this vehicle at exces-sive speeds. Go at a speed which isproper for the terrain, visibility con-ditions, and your experience.

* Never attempt to do wheelies, jumps,or other stunts.

* Always be careful when operatingthis vehicle, especially whenapproaching hills, turns, and obsta-cles and when operating on unfamil-iar or rough terrain.

* Never operate this vehicle with thecargo box lifted or removed.

* Never operate this vehicle in fast-flowing water or in water deeper thanthe floorboard.

* Never operate this vehicle with theROPS removed. The ROPS providesa structure helping to limit intrusionsby branches or other objects and mayreduce your risk of injury in acci-dents.

* Never put your hands or feet outsidethe vehicle for any reason while thevehicle is in motion. Do not hold ontothe ROPS or hip restraint bar. If youthink or feel the vehicle may tip, donot put your hands or feet outside thevehicle as they will not be able to pre-vent the vehicle from tipping. Anypart of your body (arms, legs, orhead) outside the vehicle can becrushed by passing objects, the vehi-cle, or ROPS.

* Always fasten occupant siderestraints prior to moving the vehicle.


HangtagsThis vehicle comes with hangtags containing important safety information. Anyonewho operates the vehicle should read and understand this information before riding.

HANGTAG TO GO HERE


Hangtags


Important Safety InformationAnyone who operates the ROV should read and understand this information beforeoperating this vehicle.


Warning Labels


Location of Parts and Controls

MOD026B1

MODC049G

MOD027B1

MOD030B1

MOD031B1

1. Brake Fluid Reservoir2. Gas Cap 3. Operator Side Cargo Box Tilt Lever 4. Operator Seat Belt 5. Operator Shoulder Restraint 6. Tilt Steering Wheel Lever7. Headlight Switch 8. 2WD/4WD/Rear Axle Lock

Drive Select Switches9. Ignition/Start Switch

10. DC Power Outlets11. Storage12. LCD Information Gauge13. Shift Lever14. Passenger Seat Belt15. Passenger Side Cargo Box Tilt Lever16. Engine Air Filter17. Battery18. Passenger Handhold19. Passenger Shoulder Restraint 20. Tailgate Latch21. Hitch22. Hood Release Latch23. Power Distribution Module (PDM) 24. Tie Down Hook25. Winch Fairlead Mount (if equipped)26. Coolant Reservoir27. Brake Pedal28. Accelerator Pedal29. Operator Door Release Latch30. Passenger Door Release Latch31. Winch Switch (if equipped)


Warnings

! WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction.WHAT CAN HAPPENThe risk of an accident is greatly increased if the operator does not know how tooperate this vehicle properly in different situations and on different types of terrain.HOW TO AVOID THE HAZARDAll operators of this vehicle must read and understand this Operator’s Manual andall warning and instruction labels prior to operating this vehicle.

! WARNINGPOTENTIAL HAZARDAllowing anyone under age 16 to operate this vehicle.WHAT CAN HAPPENUse of this vehicle by children can lead to serious injury or death of the child.Children under the age of 16 may not have the skills, abilities, or judgment neededto operate this vehicle safely and may be involved in a serious accident.HOW TO AVOID THE HAZARDOnly people 16 years of age or older with a valid driver’s license should operatethis vehicle.

! WARNINGPOTENTIAL HAZARDOperating or riding in the vehicle without wearing a properly secured seat belt.WHAT CAN HAPPENSerious injury or death. Occupants can strike objects in the passenger compart-ment, fall out of the vehicle during maneuvers, or be crushed or otherwise injuredin the event of an accident.HOW TO AVOID THE HAZARDALWAYS WEAR YOUR SEAT BELT and require others to wear their seat belts.See the Operation/Maintenance section of this manual for more information onusing your seat belt and both operator and passenger(s) wearing an approved hel-met.

! WARNINGPOTENTIAL HAZARDOperating this vehicle on public streets, roads, or highways.WHAT CAN HAPPENYou can collide with another vehicle.HOW TO AVOID THE HAZARDNever operate this vehicle on any public street, road, or highway.In many states it is illegal to operate a vehicle of this type on public streets, roads,or highways. Always check state and local laws and regulations.


! WARNINGPOTENTIAL HAZARDOperating or riding in this vehicle without wearing anapproved helmet, and protective gear.WHAT CAN HAPPENOperating or riding without an approved helmetincreases your chances of a serious head injury ordeath in the event of an accident.Operating or riding without eye protection can resultin an accident and increases your chances of a seri-ous injury in the event of an accident.Operating or riding without protective clothingincreases your chances of serious injury in the eventof an accident.HOW TO AVOID THE HAZARDAlways wear an approved helmet that fits properly.You should also wear: Eye protection (goggles or face shield)

GlovesBootsLong-sleeved shirt or jacketLong pants

! WARNINGPOTENTIAL HAZARDOperating this vehicle after or while consuming alcohol or drugs.WHAT CAN HAPPENCould seriously affect your judgment.Could cause you to react more slowly.Could affect your balance and perception.Could result in an accident.HOW TO AVOID THE HAZARDNever consume alcohol or drugs before or while driving this vehicle.

! WARNINGPOTENTIAL HAZARDAllowing passengers to ride in the cargo box.WHAT CAN HAPPENSerious injury or death. This vehicle is not designed to carry passengers in thecargo box. Passengers in the cargo box can be thrown around or from the vehicleduring operation or in an accident.HOW TO AVOID THE HAZARDDo not permit passengers to ride in the cargo box. Do not install any seating in thecargo box.


! WARNINGPOTENTIAL HAZARDOperating or riding in the vehicle without occupant side restraints properlysecured.WHAT CAN HAPPENSerious injury or death. Occupants or their body parts can strike objects outsidethe vehicle, be crushed by the vehicle, or fall out of the vehicle during maneuversor in the event of an accident.HOW TO AVOID THE HAZARDDo not remove the occupant side restraints. Make sure both operator and passen-ger occupant side restraints are secure before operating or riding in the vehicle.Stay seated with your seat belt and helmet on and keep your body completelyinside the vehicle during operation. See the Operation/Maintenance section of thismanual for more information.

! WARNINGPOTENTIAL HAZARDFailing to keep all parts of your body inside the passenger compartment duringoperation.WHAT CAN HAPPENSerious injury or death. Body parts could strike objects outside of vehicle or becrushed in the event of a rollover or accident.HOW TO AVOID THE HAZARDDo not place your head, arms, hands, legs, or feet outside of the passenger com-partment during operation. Stay seated with your seat belt and helmet on andoccupant side restraints properly secured. Keep your feet and legs inboard of thefoot restraints at all times. Do not attempt to stop movement or tipping of the vehi-cle with your hands or feet. If you feel the vehicle tipping, brace your feet flat onthe floor, keep hands firmly gripping the steering wheel (and handhold for outboardpassenger), and keep all body parts inside the passenger compartment.

! WARNINGPOTENTIAL HAZARDOperating this vehicle at excessive speeds.WHAT CAN HAPPENIncreases your chances of losing control of the vehicle, which can result in an acci-dent.HOW TO AVOID THE HAZARDAlways ride at a speed that is proper for the terrain, visibility, load, and operatingconditions.


! WARNINGPOTENTIAL HAZARDAttempting abrupt maneuvers, sideways sliding, skidding, fishtailing, or donuts.WHAT CAN HAPPENIncreases the chance of an accident including a rollover.HOW TO AVOID THE HAZARDNever attempt abrupt maneuvers, sideways sliding, skidding, fishtailing, or donuts.Don’t try to show off.

! WARNINGPOTENTIAL HAZARDFailure to inspect this vehicle before operating.Failure to properly maintain this vehicle.WHAT CAN HAPPENIncreases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARDAlways inspect this vehicle each time you use it to make sure it is in safe operatingcondition.Always follow the inspection and maintenance procedures and schedulesdescribed in this Operator’s Manual.

! WARNINGPOTENTIAL HAZARDFailure to use extra care when operating this vehicle on unfamiliar terrain.WHAT CAN HAPPENYou can come upon hidden rocks, bumps, or holes without enough time to react.Could result in the vehicle overturning or going out of control.HOW TO AVOID THE HAZARDGo slowly and be extra careful when operating on unfamiliar terrain.Always be alert to changing terrain conditions when operating this vehicle.

! WARNINGPOTENTIAL HAZARDFailure to use extra care when operating on rough, slippery, or loose terrain.WHAT CAN HAPPENCould cause loss of traction or control, which could result in an accident includinga rollover.HOW TO AVOID THE HAZARDDo not operate on rough, slippery, or loose terrain until you have learned and prac-ticed the skills necessary to control this vehicle on such terrain.Always be especially cautious on these kinds of terrain.


! WARNINGPOTENTIAL HAZARDFailing to use care in turns; turning too sharply or aggressively.WHAT CAN HAPPENThe vehicle could go out of control causing a collision, tip over, or rollover.HOW TO AVOID THE HAZARDAlways follow proper procedures for turning as described in this Operator’s Man-ual. Practice turning at slow speeds before attempting to turn at faster speeds. Donot turn at excessive speed or too sharply for the conditions and for your experi-ence level. See the Operation/Maintenance section of this manual for more infor-mation on turning on flat ground, hills, sand, ice, mud, or water.

! WARNINGPOTENTIAL HAZARDOperating on steep hills.WHAT CAN HAPPENThis vehicle can overturn more easily on steep hills than on level surfaces or smallhills.HOW TO AVOID THE HAZARDNever operate the vehicle on hills too steep for the vehicle or for your abilities.Practice on smaller hills before attempting larger hills.

! WARNINGPOTENTIAL HAZARDOperating with the ROPS removed.WHAT CAN HAPPENCould lead to serious injury or death.HOW TO AVOID THE HAZARDNever operate this vehicle with the ROPS removed.

! WARNINGPOTENTIAL HAZARDGoing down a hill improperly.WHAT CAN HAPPENCould cause loss of control or cause the vehicle to overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for going down hills as described in this Opera-tor’s Manual.Always check the terrain carefully before you start down any hill.Never go down a hill at high speed.Avoid going down a hill at an angle that would cause the vehicle to lean sharply toone side. Go straight down the hill where possible.


! WARNINGPOTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENCould cause loss of control or cause the vehicle to overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in this Operator’sManual.Always check the terrain carefully before you start up any hill.Never climb hills with slippery or loose surfaces.Never open the throttle suddenly or make sudden gear changes. The vehiclecould flip over backwards.Never go over the top of any hill at high speed. An obstacle, a sharp drop, oranother vehicle or person could be on the other side of the hill.

! WARNINGPOTENTIAL HAZARDCrossing hills or turning on hills.WHAT CAN HAPPENCould cause loss of control or cause the vehicle to overturn.HOW TO AVOID THE HAZARDAvoid crossing the side of a hill or turning on a hill whenever possible. Neverattempt to turn the vehicle around on any hill. If you must cross the side of a hill,drive slowly and stop or turn downhill if you feel the vehicle may tip.

! WARNINGPOTENTIAL HAZARDStalling, rolling backwards, or improperly dismounting while climbing a hill.WHAT CAN HAPPENCould result in the vehicle overturning.HOW TO AVOID THE HAZARDUse proper gear and maintain steady speed when climbing a hill.If you lose all forward speed:

Apply the brakes. Place the transmission in park after you are stopped.If you begin rolling backward:

Gradually apply the brakes while rolling backward.When fully stopped, place the transmission in park.


! WARNINGPOTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENCould cause loss of control or a collision. Could cause the vehicle to overturn.HOW TO AVOID THE HAZARDBefore operating in a new area, check for obstacles.Never attempt to ride over large obstacles, such as large rocks or fallen trees.When you go over obstacles, always follow proper procedures as described in thisOperator’s Manual.

! WARNINGPOTENTIAL HAZARDImproperly operating in reverse.WHAT CAN HAPPENYou could hit an obstacle or person behind you, resulting in serious injury or death.HOW TO AVOID THE HAZARDBefore you engage reverse gear, make sure there are no obstacles or people behind you. When it is safe to proceed, go slowly.

! WARNINGPOTENTIAL HAZARDSkidding or sliding.WHAT CAN HAPPENYou could lose control of the vehicle.You could also regain traction unexpectedly, which may cause the vehicle to overturn.HOW TO AVOID THE HAZARDLearn to safely control skidding or sliding by practicing at slow speeds and onlevel, smooth terrain.On extremely slippery surfaces, such as ice, go slowly and be very cautious inorder to reduce the chance of skidding or sliding out of control.

! WARNINGPOTENTIAL HAZARDOverloading the vehicle or carrying or towing improperly.WHAT CAN HAPPENCould cause changes in handling, which could lead to an accident.HOW TO AVOID THE HAZARDNever exceed the stated load capacity for this vehicle.Cargo should be properly distributed and securely attached.Reduce speed when carrying cargo or pulling a trailer. Allow greater distance for braking.Always follow the instructions in this Operator’s Manual for carrying cargo or pulling a trailer.


! WARNINGPOTENTIAL HAZARDOperating this vehicle through deep or fast-flowing water.WHAT CAN HAPPENTires may float, causing loss of traction and loss of control, which could lead to anaccident.HOW TO AVOID THE HAZARDNever operate this vehicle in fast-flowing water or in water deeper than the floorboard.Remember that wet brakes may have reduced stopping capability.Test the brakes after leaving water. If necessary, apply them several times to dryout the pads.

! WARNINGPOTENTIAL HAZARDOperating the vehicle with improper tires or with improper or uneven tire pressure.WHAT CAN HAPPENUse of improper tires on the vehicle, or operating the vehicle with improper oruneven tire pressure, could cause loss of control increasing your risk of accident.HOW TO AVOID THE HAZARDAlways use the size and type tires specified in this Operator’s Manual for this vehicle.Always maintain proper tire pressure as described in this Operator’s Manual.

! WARNINGPOTENTIAL HAZARDOperating this vehicle with improper modifications.WHAT CAN HAPPENImproper installation of accessories or modification of the vehicle may causechanges in handling which could lead to an accident.HOW TO AVOID THE HAZARDNever modify this vehicle through improper installation or improper use of accesso-ries. All parts and accessories added to this vehicle should be genuine Tracker OffRoad components designed for use on this vehicle and should be installed and usedaccording to instructions. If you have questions, consult an authorized Tracker OffRoad dealer.

! WARNINGPOTENTIAL HAZARDFailing to avoid pinch-points when lowering the cargo box.WHAT CAN HAPPENFingers, hands, or arms could be seriously injured when lowering the cargo box.HOW TO AVOID THE HAZARDAlways be aware of and avoid lowering cargo box until everyone is clear of pinch-points.


California Proposition 65

! WARNINGPOTENTIAL HAZARDOperating through or over thick or sharp brush, timber, debris, or rocks.WHAT CAN HAPPENSerious injury or death. Brush, branches, debris, and rocks can enter or pene-trate the passenger compartment and strike occupants. Running over sharpbranches, rocks, or other large objects can also cause loss of control.HOW TO AVOID THE HAZARDBe alert. Slow down. Wear all recommended protective gear specified in thisOperator’s Manual. Avoid operating through or over thick brush, timber, debris, orlarge rocks whenever possible. Watch for and avoid sharp branches, rocks, orother large objects that could impede or impact the vehicle or enter the passengercompartment.

! WARNINGPOTENTIAL HAZARDSecuring a person improperly in the vehicle due to physical size.WHAT CAN HAPPENSerious injury or death. Occupant could strike objects in the passenger compart-ment, fall out of the vehicle during maneuvers, or be ejected and crushed in theevent of an accident.HOW TO AVOID THE HAZARDAlways make sure a passenger can sit with both feet flat on the floor and theirback against the seat while being able to reach any provided handholds.

! WARNINGPOTENTIAL HAZARDOperating this vehicle on paved surfaces.WHAT CAN HAPPENThe vehicle’s tires are designed for off-road use only, not for use on pavement.Paved surfaces may seriously affect handling and control of the vehicle and maycause the vehicle to go out of control.HOW TO AVOID THE HAZARDWhenever possible, avoid operating the vehicle on any paved surfaces includingsidewalks, driveways, parking lots, and streets. If operating on paved surfaces isunavoidable, travel slowly (less than 10 mph [16 km/h]) and avoid sudden turnsand stops.

! WARNINGThe Engine Exhaust from this product contains chemicalsknown to the State of California to cause cancer, birthdefects or other reproductive harm.


Division II — Operation/MaintenanceSpecifications

Specifications subject to change without notice.

ENGINEType Four-Cycle/Liquid-CooledBore 72 mm (2.835 in.)Stroke 66.5 mm (2.618 in.)Displacement 812 cc (49.55 cu in.)Spark Plug F6RTC (p/n 3040-031)Spark Plug Gap 1.0 mm (± 0.1 mm)Target Idle RPM 950 ± 25Max RPM 6300CHASSISLength (Overall) 320.04 cm (126 in.) (800SX)

324.62 cm (127.8 in.) (800SX LE)Height (Overall) 187.96 cm (74 in.)Width (Overall) 160.02 cm (63 in.)Suspension Travel (Front/Rear) 25.4 cm (10 in.) / 24.1 cm (9.5 in.)Tire Size (Front) 26H x 10W R14 (800SX)

27H x 9W R14 (800SX LE)Tire Size (Rear) 26H x 10W R14 (800SX)

27H x 11W R14 (800SX LE)Front Tire Inflation Pressure (No Cargo) (w/Cargo)

12 psi (82.7 kPa)12 psi (82.7 kPa)

Rear Tire Inflation Pressure (No Cargo) (w/Cargo)

14 psi (96.5 kPa)16 psi (110.3 kPa)

MISCELLANEOUSDry Weight (Approx) 724.4 kg (1597 lb) (800SX)

778.9 kg (1717 lb) (800SX LE)Curb Weight 759.8 kg (1675 lb) (800SX)

814.2 kg (1795 lb) (800SX LE)ROPS Tested Curb Weight 1587.6 kg (3500 lb)Gas Tank Capacity 37.85 L (10 U.S. gal.)Coolant Capacity 5.67 L (6 U.S. qt)Differential Capacity 198 ml (6.7 fl oz) Transaxle Capacity 1.21 L (41.0 fl oz) Engine Oil Capacity (Approx) 2.37 L (2.5 U.S. qt)Gas (Recommended) Regular unleaded 87 octane (R+M)/2,

ethanol content not to exceed 10%Engine Oil (Recommended) 0W-40 (Synthetic)Front Differential Lubricant SAE-Approved 80W-90 HypoidTransaxle Lubricant Transaxle Fluid with EPTaillight/Brake Light 12.8V-27W/14V-8WHeadlight 12V/60W/55WStarting System ElectricBrake Type Four-Wheel Hydraulic Disc Brake

20

Vehicle OperationPre-Start/Pre-Operation Checklist

Item RemarksBrake System Pedal firm — near top of travel.

Fluid at proper level.Check for fluid leaks.

Controls Steering free — no binding — no excessive free-play.Shift lever in park.Accelerator free — no binding — returns to idle position.

Fluids Coolant level to bottom of radiator neck.Check oil level.Gas tank full of recommended gasoline.Differential/rear drive at proper level.Check for fluid leaks.

Suspension Ball joints/tie rod ends free — secure.Shocks not leaking — mountings secure.Shock spring preload equal on left and right.Components free of all debris.

Lights/Switches Check light bar, light bar w/high beam, and light bar w/low beam — light switch to OFF.Check taillight/brake light — light switch to OFF.Check drive select switch — set to 2WD.

Air Filter Clean-out valve clear of all debris.Ducting secure — no holes or tears.

Tires/Wheels Properly inflated — tread adequate.Check tires for cuts or tears.Wheels secure to hubs — hubs secure to axles.Check wheels for cracked or bent rims.

Seat Belts/Restraints Check condition — proper operation — proper adjustment.

Nuts/Bolts/Fasteners Check for loose nuts and bolts — tighten as necessary.Check fasteners — latches — ROPS.Secure hood, cargo box and seats.

21

Vehicle OperationStarting the EngineAlways start with the vehicle on a flat, levelsurface. Carbon monoxide poisoning cankill you, so keep the vehicle outside whileit’s running. Follow these steps to start it up:

1. Step into the vehicle and sit down; thenfasten the operator seat belt and thepassenger seat belts (if applicable) andsecure your approved helmet or hardhat (if applicable) and require your pas-senger(s) to do the same (if applicable).Check that the occupant side restraintsare secured in place.

2. Place the transmission in park; thendepress the brake pedal.

3. Turn the ignition key clockwise to theSTART position; then when theengine starts, release to the RUNposition. Do not increase engine RPMabove idle.

4. Let the engine warm up to normaloperating temperature.

Shifting Transaxle

NOTE: When shifting, the opera-tor is selecting a drive range in thetransaxle and not in the Continu-ously Variable Transmission (CVT).The CVT is fully automatic andshifts as a function of engine RPMand vehicle loading.

MOD057A

1. To select reverse gear from park,move the shift lever downward oneposition until the letter “R” is dis-played on the LCD informationgauge.

2. To select neutral from reverse, movethe shift lever downward one positionuntil the letter “N” is displayed on theLCD information gauge.

3. To select high range from neutral,move the shift lever downward oneposition until the letter “H” is dis-played on the LCD informationgauge.

4. To select low range from high range,move the shift lever downward oneposition until the letter “L” is dis-played on the LCD informationgauge.

! WARNINGFalling from a moving vehicle couldresult in serious injury or death.Always fasten your seat belt securelyand ensure the passenger seat belt isproperly and securely fastened priorto operating or riding in this vehicle.

CAUTIONDo not run the starter motor for morethan 15 seconds per starting attempt.The starter motor may overheat caus-ing severe starter motor damage.Allow 60 seconds between startingattempts to allow the starter motor tocool.

CAUTIONAlways come to a complete stop andallow the engine to return to idlebefore attempting to shift from onerange to the other or into reverse.Always shift on level ground.

22

NOTE: The high range is for nor-mal driving with light loads. The lowrange is for carrying heavy loads ortrailer towing. Compared to HIGHrange, the LOW range position pro-vides slower speed and greatertorque to the wheels.

5. To select park, move the shift levercompletely up until the letter “P” isdisplayed on the LCD informationgauge.

Driving the VehicleOnce the engine is at normal operatingtemperature, the vehicle is ready to bedriven.

1. With the engine idling, press the footbrake pedal to apply the brake; thenselect the appropriate operating rangeand/or direction with the shift lever.

2. Release the foot brake pedal andpress the accelerator to slowly addpower to start moving.

3. To slow down or stop, release theaccelerator and press the foot brakepedal as necessary to slow or stop thevehicle.

Braking/StoppingAlways allow plenty of room and time tostop smoothly. Sometimes quick stopsare inevitable, so always be prepared.Whether you’re stopping slowly or stop-ping quickly, do this:

1. Release the accelerator; then press thefoot brake pedal to apply the brake.

2. If the wheels lock, release them for asecond; then apply them again. Onsurfaces such as ice, mud, or loosegravel, pump the brake pedal rapidly.

3. Never “ride” the brake. Even main-taining minimal pressure on the brakepedal will cause the brake pads todrag on the disc and may overheat thebrake fluid.

ParkingParking involves following the previousrules for braking; then:

1. After the vehicle stops, shift intopark.

2. Turn off the ignition.3. If you have to park on a hill, block the

wheels on the downhill side.

Basic TurnsSteering effort is at its lowest in two-wheeldrive (2WD). Greater effort is neededwhen in four-wheel drive (4WD). Thegreatest effort is needed when in four-wheel drive and the rear differential islocked.Slow down before entering a turn. Thebasic turning technique is to drive at lowspeed and gradually adjust the amount ofsteering to suit the driving surface. Donot make sudden sharp turns on any sur-face. Refer to the sub-sections DrivingUphill, Driving Downhill, CrossingObstacles, Driving in Reverse, Skiddingor Sliding, Crossing Water, or CrossingRoads for more information.

CAUTIONAlways shift into low range whenoperating on wet or uneven terrain,when towing or pushing heavy loads,and when using a plow. Failure to fol-low this caution may result in prema-ture V-belt failure or in damage torelated drive system components.

CAUTIONNever increase engine speed aboveidle RPM when in park or belt damagewill occur.

! WARNINGExcessive repetitive use of thehydraulic brake for high speed stopswill cause overheating of the brakefluid and premature brake pad wearwhich will result in an unexpectedloss of brakes.

! WARNINGUse only manufacturer-approvedbrake fluid. Never substitute or mixdifferent types or grades of brakefluid. Brake loss can result. Checkbrake fluid level and pad wear beforeeach use. Brake loss can result inserious injury or death.

23

If your vehicle ever skids sideways duringa turn, steer in the direction of the skid.Also, avoid hard braking or acceleratinguntil you have regained directional control.

Driving UphillAlways drive straight up the hill andalways avoid hills that are very steep.

1. Keep both hands on the wheel.2. Prior to starting the climb, shift into

low range, select four-wheel drive fortraction, and gradually press the accel-erator; then maintain a constant speed.

3. If the vehicle stalls on a hill, press thefoot brake pedal to apply the brake,shift into reverse, and slowly backdown the hill. Do not attempt to turnaround on a hill.

Driving DownhillAlways drive straight down the hill andalways avoid hills that are very steep.

1. Keep both hands on the wheel.

2. Prior to descending the hill, shift intolow range and release the acceleratorto allow maximum engine braking.Do not use four-wheel drive whendescending a hill. Engine braking cancause the front wheels to slide reduc-ing steering control.

NOTE: Use minimum braking (asnecessary) to maintain a slowspeed.

Crossing ObstaclesCrossing obstacles can be hazardous.There is always the possibility of thevehicle tipping. If you cannot go aroundan obstacle, follow these guidelines:

1. Stop the vehicle and place the trans-mission in park. Go out to inspect theobstacle thoroughly from both yourapproach side and the exit side. If youbelieve you can cross the obstaclesafely, select four-wheel drive(4WD).

NOTE: Selecting the LOCK posi-tion on the rear differential lockswitch may be beneficial.

2. Approach the obstacle as close aspossible to 90° to minimize vehicletipping.

3. Keep speed slow enough to maintaincontrol but fast enough to maintainmomentum.

! WARNINGUse care in turns — turning the steer-ing wheel too far or too fast can resultin loss of control or a rollover. Exces-sive speed, driving aggressively, ormaking abrupt maneuvers, even onflat, open areas, can cause loss ofcontrol, tipping, or rollover. Uneventerrain, rough terrain, soft surfaces,slippery surfaces, and paved sur-faces can also cause a loss of controlor rollover in a turn. On loose or softsurfaces, allow yourself more timeand distance to turn and slow down.

! WARNINGDo not attempt to turn around on ahill.

! WARNINGDriving up hills improperly can causeloss of control of the vehicle resultingin serious injury or death. Use extremecare when driving in hilly terrain.

! WARNINGDo not attempt to turn around on ahill.

! WARNINGDriving down hills improperly cancause loss of control of the vehicleresulting in serious injury or death.Never drive downhill at a high rate ofspeed. Use extreme care when driv-ing in hilly terrain.

24

4. Use only enough power to cross theobstacle but still give yourself plentyof time to react to changes in condi-tions. Crawl over the obstacle.

NOTE: If there is any questionabout your ability to cross theobstacle safely, you should turnaround if the ground is flat and youhave room or back up until you finda less difficult path.

Driving in ReverseWhen operating in reverse, avoid sharpturns and backing down a hill. Whenusing reverse, follow these guidelines:

1. Back up slowly. It’s hard to seebehind you.

NOTE: Avoid sudden brakingwhile backing up.

2. If possible, it is advisable to havesomeone “spotting” for you whilebacking up.

3. If you are unsure of what is behindthe vehicle, place the transmission inpark and get out and inspect the areabehind.

NOTE: This vehicle is equippedwith a reverse limiter that is acti-vated when the vehicle is in reverseand 2WD. The reverse limiter willlimit the speed and RPM while driv-ing in reverse. To override thereverse limiter, 4WD must beselected while in reverse.

Skidding or SlidingIf you lose control after hitting sand, ice,mud, or water, follow these guidelines:

1. Turn the steering wheel into the direc-tion of the slide.

2. Keep your foot off the brake untilyou’re out of the skid.

3. Stop and shift into four-wheel drive.

Crossing WaterThis vehicle can only operate in water upto its floorboard. Stay away from fast-moving rivers. This vehicle’s tires can bebuoyant. In deep water, the vehicle maylose traction due to floating.

1. Physically check the depth and cur-rent of the water, especially if youcan’t see the bottom. Also, check forboulders, logs, or any other hiddenobstacles.

2. Keep speed slow while maintainingmomentum.

3. Make sure you have a way out on theother side of the water.

4. Once you’ve cleared the water,briefly apply the brakes to make surethey work.

NOTE: Light pedal pressure orpumping the brakes for a short dis-tance will aid in drying the brakes.

Crossing RoadsIt may be necessary to cross a road orhighway. If so, note the following guide-lines:

1. Stop completely on the shoulder ofthe road.

2. Check both directions for traffic.3. Crossing near a blind corner or inter-

section is dangerous; avoid it if at allpossible.

4. Drive straight across to the oppositeshoulder.

5. Take into account that this vehiclecould stall while crossing; give your-self enough time to get off the road.

! WARNINGStriking hidden obstacles can causeserious injury or death. Reducespeed and proceed with care in unfa-miliar terrain.

! WARNINGDo not operate this vehicle on a fro-zen body of water unless you havefirst verified the ice is sufficientlythick to support the vehicle, cargo,and participants. The vehicle couldbreak through the ice causing seri-ous injury or death.

25

6. You have to assume that oncomingcars don’t see you, and if they do,they won’t be able to predict youractions.

7. It’s illegal to cross public roads insome places. Know your local laws.

Plan AheadAlways bring basic items to make yourexperience safe and enjoyable. Be pre-pared for whatever you may encounter.

• First-aid kit*• Food and water• Tool kit*• Cell phone

*Storage locations and potential storagelocations are covered later on in thismanual.

26

General InformationNOTE: This vehicle is equippedwith a speed limitation device tolimit the speed to 15 mph (24 km/h)if the operator’s seat belt is not fullyengaged. The seat belt indicatorlight will remain illuminated untilthe operator’s seat belt is fullyengaged.

Control Locations and FunctionsIgnition Switch KeyTwo keys come with this vehicle. Keep thespare key in a safe place. An identifyingnumber is stamped on each key. Use thisnumber when ordering a replacement key.Ignition SwitchThe ignition switch has three positions.

ATV-0056A

OFF position — All electrical circuitsexcept the accessory are off. The enginewill not start. The key can be removed inthis position.NOTE: The accessory plugs arepowered by the battery at all times.RUN position — The starter circuit iscomplete and the engine can run. The keycannot be removed in this position.START position — The starter circuit iscomplete and the starter is engaged.When the key is released, the switch willreturn to the RUN position. The key can-not be removed in this position.NOTE: This vehicle has safetyinterlock switches which preventthe starter motor from activatingwhen the brake pedal is notdepressed.

Shift LeverThis vehicle has a Continuously VariableTransmission (CVT) which transferspower to the dual range transmission.High range, low range, neutral, reverseand park are selected by the operator withthe shift lever.

MOD700

Drive Select Switches

MOD184

The left-hand 2WD/4WD switch allowsthe operator to operate the vehicle ineither two-wheel drive (rear wheels) orfour-wheel drive (all wheels). The right-hand switch allows the operator tomechanically lock the rear axle to applyequal power to both rear wheels. Bothswitches can be used together to achieve4WD rear axle lock.For normal driving on flat, dry, and hardsurfaces, two-wheel drive without rearaxle lock should be sufficient. NOTE: This vehicle is equippedwith a reverse limiter that is acti-vated when the vehicle is in reverseand 2WD. The reverse limiter willlimit the speed and RPM while driv-ing in reverse. To override thereverse limiter, 4WD must beselected while in reverse.

27

In situations when additional traction isnecessary, rear axle lock or four-wheeldrive would be the desired choice. Somesituations may require four-wheel driveand rear axle lock.Drive Selection

MOD184

To select 2WD, depress the bottom of the2WD/4WD switch. To select 4WD, movethe switch to the opposite position. Toengage the rear axle lock, push the top ofthe rear axle lock switch.The indicator will change with eachselection.

MOD339

NOTE: Maneuverability and han-dling characteristics will differ withthe rear axle lock engaged.Foot BrakeThe foot brake is the only service brake,and it should be applied whenever brak-ing is needed.Apply the brake by pressing the brakepedal down.

Steering Wheel Tilt LatchPull on the lever located on the steeringcolumn and move the steering wheel tothe desired position; then release thelever and make sure the steering wheellocks securely.

MOD183

Headlight Switch

MODC036

With the ignition switch in the RUNposition, use the headlight switch toselect low beam or high beam. Thetaillights work in all positions exceptOFF. The brake lights work in all lightpositions.Accelerator PedalPress down on the pedal to increaseengine RPM and vehicle speed; releasethe pedal to decrease engine RPM andvehicle speed.NOTE: This vehicle is equippedwith an RPM limiter that retards theelectronic throttle body, fuel injec-tors and ignition timing when maxi-mum RPM is approached.

! WARNINGMake sure the steering wheel is lockedsecurely in place before moving thevehicle, or steering wheel movementcould occur causing loss of control.

28

Operator Seat1. The operator’s seat is not removable

without tools.2. To lock the seat into position, slide

the rear of the seat into the seat retain-ers and push down firmly on the frontof seat. The seat must engage theretainers and lock into position.

Passenger Seats1. To remove a seat, lift up on the front

of the seat; then raise the front of theseat and slide it out of its rear retain-ers.

2. To lock the seat into position, slidethe rear of the seat into the seat retain-ers and push down firmly on the frontof seat. The seat must engage theretainers and lock into position.

Seat BeltsNOTE: This vehicle is equippedwith a speed limitation device tolimit the speed to 15 mph (24 km/h)if the operator’s seat belt is not fullyengaged. The seat belt indicatorlight will remain illuminated untilthe operator’s seat belt is fullyengaged.This vehicle is equipped with seat beltsfor the operator and the passenger(s). Tofasten and release the seat belt properly,use the following procedure:

1. Place the seat belt across your lap aslow as possible without twisting thebelt, making sure the shoulder strap isbelow the neck and across the chest.

2. Push the latch plate into the buckleslot until it “clicks” and latchessecurely. The belt will retract whenthe buckle is released.

Doors and Shoulder BarsIn addition to the seat belts, there are left-and right-side doors and shoulder bars torestrict arms or legs from extending out-side the vehicle. The doors should alwaysbe secured when the vehicle is moving.Never operate the vehicle with the doorsor shoulder bars removed or not secured.

Cargo Box Tie-Downs The cargo box has numerous tie-downlocations around the top perimeter and ineach corner of the cargo box floor.Always secure cargo with tie-downstraps to avoid shifting or damage tocargo.Tie-down locations (1) should not beused as a sole tie-down location forheavy loads.Use tie-down locations (2) as the main tiepoint to secure heavy loads and tie-downlocations (1) as a secondary tie point.

! WARNINGMake sure the seat is secure beforedriving the vehicle. Serious injury ordeath could result if the seat is notproperly secured.

! WARNINGMake sure the seats are securebefore driving the vehicle. Seriousinjury or death could result if theseats are not properly secured.

! WARNINGOnly appropriate-sized passengersmay ride in this vehicle. Passengersmust be able to place both feet flat onthe floor while keeping their backagainst the back of the seat and hold-ing on to the handholds (outboardpassenger only).

! WARNINGFalling outside a moving vehicle couldresult in serious injury or death. Alwaysfasten your seat belt securely andensure the passenger seat belt is prop-erly and securely fastened prior to oper-ating or riding in this vehicle.

29

MOD118A

NOTE: Always refer to the LoadCapacity Ratings chart in this man-ual when loading and haulingcargo.

Tailgate Latches

MOD701A

1. To open the tailgate, pull the latchhandles (1) (located on the end of thetailgate).

2. To close the tailgate, lift up and pushforward firmly. Hook the latch bails (2)and push the handles forward over cen-ter.

MOD109A

Cargo Box Latch Handles

MOD062A

1. To raise the cargo box, lift the handleupward; then raise the cargo box.

2. To lower the cargo box, push downfirmly on the front of the box. The boxwill automatically lock into position.

Behind-Seat StorageA storage compartment is located behindthe passenger seats. This storage locationis not watertight. A first-aid kit, fire extinguisher and vehi-cle recovery equipment can be stored inthis location. Fire extinguishers shouldbe secured and not allowed to rollaround.If emergency equipment is stored out ofsight, be sure to clearly identify the loca-tions of those items.

MOD122

CAUTIONWhen using ratchet-type straps, donot over tighten or damage to thecargo box could occur.

30

To access behind-the-seat storage, turnthe 1/4-turn fastener clockwise and tiltthe seat backrest forward.

MOD121A

The storage compartment is designed tobe a perfect fit for the passenger seat bot-tom(s).

1. Fold the passenger seat backrest(s)down and place the seat bottom(s)into the marked holding position(s) inthe storage compartment.

MOD151A

Power Steering (if equipped)Certain vehicles were produced with anElectronic Power Steering (EPS) systemto reduce steering effort and operatorfatigue over a broad range of operatingconditions. The EPS system engages when the igni-tion switch is turned to the ON positionand disengages after approximately fiveminutes (to conserve battery power) ifthe engine is not running.This system is entirely maintenance-free:no adjustment or servicing is required.There are no fluids to check or change,and the EPS system is entirely self-con-tained and sealed to protect it from theelements.

The EPS system is battery system pow-ered; therefore, the battery must be ingood condition and fully charged. Powerdelivery and overload protection is pro-vided by an EPS relay and 30-amp fuselocated under the hood in the Power Dis-tribution Module (PDM).The system is self-monitored and willdisplay a malfunction code on the LCDinformation gauge should an EPS systemcontrol circuit problem occur.

Code Fault DescriptionC1351 Motor Position IndexC1352 Motor Position PlausibilityC1353 Motor Position RangeC1354 Internal Voltage SupplyC1355 Session ErrorC1356 Torque Sensor Open CircuitC1357 Torque Sensor RangeC1358 Torque Sensor Over RangeC1359 Torque Sensor CommunicationC1360 Internal Processor ErrorC1361 Temperature Sensor CircuitC1362 Stuck at BootloaderC1363 Calibration Values Not ProgrammedC1364 Calibration ChecksumC1365 Application ChecksumC1366 Variant Coding ErrorC1367 Vehicle SpeedC1368 ECM CAN Bus ErrorC1369 Gauge CAN Bus ErrorC1370 CAN Bus ErrorC1371 Over Temp ConditionC1372 Battery Voltage LowC1373 Battery Voltage HighC1374 Over Current ErrorC1375 System Voltage HighC1376 Current Sensor Range

31

NOTE: The code reset procedure isto turn the key switch to the OFF posi-tion, then back to the ON position. Ifthe code continues to be displayed,take your vehicle to an authorizeddealer for EPS system servicingbefore resuming operation.

In the event of electrical power failure,the EPS system becomes disabled (simi-lar to an automobile with the engine shutoff). Steering effort increases but steeringcontrol can be maintained.

LCD Information Gauge (Digital)

MOD338

(1) Left Button — Shifts top displaythrough speedometer, RPM, andclock.

(2) Middle Button — Shifts middle dis-play through speedometer, RPM,clock, odometer, trip 1, trip 2, andengine hours.

(3) Right Button — Shifts bottom displaythrough coolant temperature, batteryvoltage, and fuel level.

(4) Speedometer/Tachometer/Clock Dis-play — Indicates approximate vehiclespeed in MPH or KM/H when speed-ometer function is selected, RPMwhen tachometer function is selected,or time when clock is selected. Pressthe Left Button to change whichparameter is being displayed. Withspeedometer selected, press and holdthe Left Button to shift between stan-dard (mph/miles/Fahrenheit) andmetric (km/h/kilometers/Celsius).With the clock mode selected, pressand hold the Left Button to start theprocess to set the clock. The option ofselecting the 12-hour or 24-hourclock is available; press the Left But-ton to alternate between the twomodes. Next, press the Middle Buttonto choose the hour and minutes. Pressthe Left or Right Button to set thehour; then press the Middle Button tochoose the minutes. Press the Left orRight Button to set the minutes.When the proper time has been set,press the Middle Button to return tothe main gauge display.

(5) Engine Hour Meter/Odometer/TripMeter/Speedometer/Tachometer/Clock Display — Displays enginehours, odometer, trip meter, speedom-eter, tachometer, or clock. Press theMiddle Button to change whichparameter is being displayed. TheEngine Hour Meter and Odometercannot be reset. To reset the tripmeter, select the Trip Meter; thenpress and hold the Middle Buttonuntil the trip meter display reads 0.

NOTE: The engine hour meter willnot activate until engine speedexceeds 500 RPM.

NOTE: An item can only be dis-played in the middle position (5) if itis not already displayed in the topposition (4). To set the clock whenthe clock is in the middle position,press and hold the Middle Button;then use the procedure found in 4.

CAUTIONNever operate this vehicle with anEPS code indicated on the LCD infor-mation gauge that cannot be turnedoff using the reset procedure. Thisindicates a malfunction in the EPSsystem control circuit and couldresult in a loss of power steeringassist.

32

(6) Coolant Temperature/Battery Volt-age/Fuel Level Display — Displayscoolant temperature, battery voltage,and fuel quantity. Press the Right But-ton to change which parameter isbeing displayed. Press and hold theRight Button to see the actual valuesassociated with the mode selected.

NOTE: High engine RPM, lowvehicle speed, or heavy load canraise engine temperature. Decreas-ing engine RPM, reducing load, andselecting an appropriate transmis-sion gear can lower the tempera-ture.

NOTE: Debris in the engine com-partment (or packed between thecooling fins of the radiator) canreduce cooling capacity. Using agarden hose, wash the radiator andthe engine to remove any debrispreventing air flow.

(7) Gear Position Indicator — Indicateswhich gear is selected.

(8) Rear Axle Lock Indicator — Displaysan X between rear wheels when theaxle lock has been engaged. Displaysan O between rear wheels when theaxle lock is disengaged.

(9) Drive Select Indicator — Displays anO between the front wheels when the4WD drive mode is selected by thedrive select switch.

(10) Seat Belt Reminder Indicator — Eachtime the ignition switch is turned ON,the indicator will illuminate on thespeedometer until the operator’s seatbelt is secured to remind occupants tosecure their seat belts.

(11) Electronic Fuel Injection (EFI) Mal-function Indicator — A diagnostictrouble code (see list) and engine iconwill be displayed on the LCD infor-mation gauge whenever an EFI erroris detected. The code and engine iconwill continue to be displayed on theLCD information gauge until theerror is corrected.

MOD102A

NOTE: Take the vehicle to anauthorized dealer to have the errorcorrected and the system errorreset as soon as possible.

CAUTIONContinued operation with high enginetemperature may result in enginedamage or premature wear.

CAUTIONThe manufacturer does not recom-mend using a pressure washer toclean the radiator core. The pressuremay bend or flatten the fins causingrestricted air flow, and electrical com-ponents on the radiator could bedamaged. Use only a garden hosewith spray nozzle at normal tap pres-sure.

! WARNINGThe seat belt indicator and RPM lim-iter are a reminder and will turn offafter the operator’s seat belt issecured. It does not indicate that allseat belts are properly secured. It isthe operator’s responsibility toensure all vehicle occupants areproperly seated with seat beltssecure and doors are properlylatched. Serious injury or death couldoccur as a result of falling outside amoving vehicle.

33

Diagnostic Trouble Codes

Display Fault DescriptionC0063 Tilt Sensor Circuit HighC0064 Tilt Sensor Circuit Low/SG/OpenC1263 Backup/Reverse Circuit OpenC1264 Backup/Reverse Buzzer Circuit HighC1265 Backup/Reverse Circuit Low/SGP0030 Oxygen Heater Intermittent/OpenP0031 Oxygen Heater Low/SGP0032 Oxygen Heater High/SPP0068 Throttle Position Sensor MAP Plausi-

bilityP0107 MAP Sensor Circuit Low/SG/OpenP0108 MAP Sensor Circuit High/SPP0112 Intake Air Temp Sensor Circuit Low/

SGP0113 Intake Air Temp Sensor Circuit High/

OpenP0114 Intake Air Temp Sensor Circuit Inter-

mittentP0116 Engine Coolant Temp Sensor Circuit

Range/PerformanceP0117 Engine Coolant Temp Sensor Circuit

Low/SGP0118 Engine Coolant Temp Sensor Circuit

High/Open/SPP0122 Throttle Position Sensor #1 Circuit

Low/SGP0123 Throttle Position Sensor #1 Circuit

High/OpenP0130 Oxygen Sensor Intermittent/OpenP0131 Oxygen Sensor Low/SG or Air-LeakP0132 Oxygen Sensor High/SPP0171 Oxygen Feedback Below Minimum

CorrectionP0172 Oxygen Feedback Exceeds Maximum

CorrectionP0201 Cylinder #1 Fuel Injector Circuit OpenP0202 Cylinder #2 Fuel Injector Circuit OpenP0203 Cylinder #3 Fuel Injector Circuit OpenP0217 Engine Coolant Over Temperature

DetectedP0219 Engine Over-Speed ConditionP0222 Throttle Position Sensor #2 Circuit

Low/SG/OpenP0223 Throttle Position Sensor #2 Circuit

HighP0261 Cylinder #1 Fuel Injector Circuit Low/

SGP0262 Cylinder #1 Fuel Injector Circuit HighP0264 Cylinder #2 Fuel Injector Circuit Low/

SGP0265 Cylinder #2 Fuel Injector Circuit High

P0267 Cylinder #3 Fuel Injector Circuit Low/SG

P0268 Cylinder #3 Fuel Injector Circuit HighP0325 Knock Sensor Range/PerformanceP0326 Knock Sensor Intermittent/ErraticP0363 Misfire Detected — Fueling DisabledP0370 Loss of Crankshaft Position Sensor

Synchronization/Gap PositionP0371 Crankshaft Position Sensor Additional

Teeth DetectedP0372 Crankshaft Position Sensor Missing

ToothP0373 Crankshaft Position Sensor Spike

DetectedP0374 Crankshaft Position Sensor Signal

Not DetectedP0444 EVAP System Purge Control Valve

Circuit OpenP0458 EVAP System Purge Control Valve

Circuit Low/SGP0459 EVAP System Purge Control Valve

Circuit High/SPP0480 Fan-Primary Relay Control Circuit

OpenP0481 Fan-Secondary Relay Control Circuit

OpenP0500 Vehicle Speed-SensorP0503 Vehicle Speed Sensor Circuit Intermit-

tent/Erratic/HighP0504 Brake Switch PriorityP0562 System Voltage LowP0563 System Voltage HighP0600 Serial Communication LinkP0606 Internal Monitoring ErrorP060C Internal Monitoring 3 ErrorP0615 Starter Relay CircuitP0616 Starter Relay Circuit LowP0617 Starter Relay Circuit HighP061A Internal Monitoring of Torque ErrorP061F Electronic Throttle Control Driver

Temperature WarningP0627 Fuel Pump Control Circuit OpenP0628 Fuel Pump Control Circuit Low/SGP0629 Fuel Pump Control Circuit High/SPP0630 VIN Not Programmed or IncompatibleP0641 Sensor Reference Voltage #1 Circuit

Low/OpenP0643 Sensor Reference Voltage #1 Circuit

HighP0651 Sensor Reference Voltage #2 Circuit

Low/OpenP0653 Sensor Reference Voltage #2 Circuit

High

Display Fault Description

34

Speed LimiterThis vehicle is equipped with a speedlimiter that can be changed through theLCD information gauge. To change orcheck the speed limiter, use the followingprocedure:NOTE: The three buttons on thegauge are the left (A), middle (B),and right (C).

MOD258

1. Turn the ignition switch to the RUNposition.

2. Hold the left and right buttons of thegauge simultaneously until DIAG-NOSTIC MENU is displayed.

3. Scroll up by pressing the right buttonor down by pressing the left buttonuntil ADVANCED is displayed; thenpress the middle button to SELECT.

P0685 EFI/Main Relay Circuit OpenP0686 EFI/Main Relay Circuit Low/SGP0687 EFI/Main Relay Circuit High/SPP0691 Fan-Primary Relay Control Circuit

Low/SGP0692 Fan-Primary Relay Control Circuit

High/SPP0693 Fan-Secondary Relay Control Circuit

Low/SGP0694 Fan-Secondary Relay Control Circuit

High/SPP1120 Throttle Position Sensor Lower Posi-

tionP1121 Throttle Position Sensor Lower Adap-

tionP1122 Throttle Position Sensor Lower

ReturnP1123 Throttle Position Sensor Adaption

ConditionP1124 Throttle Position Sensor Limp Home

AdaptionP1125 Throttle Position Sensor Upper Posi-

tionP1126 Throttle Position Sensor Upper

ReturnP2100 Throttle Actuator Control Motor Circuit

OpenP2102 Throttle Actuator #1 Control Motor

Circuit Low/SGP2103 Throttle Actuator #1 Control Motor

Circuit High/SPP2106 Electronic Throttle Control Output Is

Out Of RangeP2107 Electronic Throttle Control Driver

Over-TemperatureP210C Throttle Actuator #2 Control Motor

Circuit Low/SGP210D Throttle Actuator #2 Control Motor

Circuit High/SPP2118 Throttle Actuator Control Motor

Range ErrorP2119 Throttle Control Actuator Control Per-

formance ErrorP2122 Pedal Position Sensor #1 Circuit Low/

Open/SGP2123 Pedal Position Sensor #1 Circuit

High/SPP2127 Pedal Position Sensor #2 Circuit Low/

Open/SGP2128 Pedal Position Sensor #2 Circuit

High/SPP2135 Throttle Position Sensor Plausibility

ErrorP2138 Pedal Position Sensor Plausibility

Error

Display Fault DescriptionP2299 Brake Pedal Position/Accelerator

Pedal Position IncompatibleP2300 Ignition Coil #1 Primary Circuit Low/

SG/OpenP2301 Ignition Coil #1 Primary Circuit HighP2303 Ignition Coil #2 Primary Circuit Low/

OpenP2304 Ignition Coil #2 Primary Circuit HighP2306 Ignition Coil #3 Primary Circuit Low/

OpenP2307 Ignition Coil #3 Primary Circuit HighP2610 ECU Warm ResetU0100 Lost Communication with ECMU0155 LCD Gauge to ECM CAN Communi-

cation LostFUEL OFF

Tilt Sensor Activation Code

Display Fault Description

35

MOD255

4. Scroll up by pressing the right buttonor down by pressing the left buttonuntil VEH SPEED is displayed. Thisis the menu to set the speed limiter;press the middle button to SELECT.

MOD256

5. Scroll up by pressing the right buttonor down by pressing the left buttonuntil the desired speed limiter value isachieved; then press the middle but-ton to SET. To password protect thelimited speed, proceed to step 6. Ifpassword protection is not desired,exit this menu by scrolling up withthe right button or down with the leftbutton until EXIT is displayed; thenpress the middle button to SET.

MOD294

6. To password protect the limitedspeed, scroll up by pressing the rightbutton or down by pressing the leftbutton until ADV PASSWD is dis-played; then press the middle buttonto SELECT.

MOD259

NOTE: When ADV PASSWD isenabled, entering a password tonavigate into the ADVANCED menuis required. For this reason, it isrecommended to write down thecode and store in a safe place. If thecode is forgotten, the vehicle mustbe taken to an authorized dealer tobe reset.

7. Scroll up by pressing the right buttonor down by pressing the left buttonuntil ADV PASSWD ENABLE isdisplayed; then press the middle but-ton to SET.

MOD260

8. Enter the desired code one digit at atime by pressing the right button orleft button until the desired number isachieved and pressing the middle but-ton to SET; then repeat until all fournumbers are entered and set.

9. To exit this menu, scroll up by press-ing the right button or down by press-ing the left button until EXIT isdisplayed; then press the middle but-ton to SELECT.

36

Oil Level StickThere is an oil level stick for checkingthe engine oil level. To check the oillevel, use the following procedure:NOTE: The vehicle should be onlevel ground when checking theengine oil level.

1. Lift the cargo box.2. Remove the oil level stick and wipe it

with a clean cloth.

MOD021A

3. Install the oil level stick.NOTE: The oil level stick should befully seated for checking purposes.

4. Remove the oil level stick; the engineoil level should be within the operat-ing range.

MOD-OIL-GA

5. To add oil, the cargo box must betilted up. Remove the oil fill cap.After adding oil, install the oil fill capand tighten securely.

MOD064

6. Check the oil level after additional oilis added to the engine and confirm theoil is within the operating range.

Load Capacity Ratings Chart This vehicle must always be loaded inaccordance with the Load Capacity Ratingschart. Under no circumstances should theVehicle Load Capacity (Payload) ratingever be exceeded.

Vehicle Load Capacity (Payload) —Total weight of operator, passenger(s),trailer tongue weight, accessories, cargo,and storage compartments. Any combina-tion of these must not exceed 1500 lb(680 kg).Tongue Weight — Weight on trailertongue.Accessory Weight — Winch, gun scab-bard brackets, snow plow, etc.Rear Tongue and Cargo Weight —Total weight on trailer tongue and cargo box.Rear Tongue, Cargo, and StorageCompartments Weight — Total weighton trailer tongue, cargo box, and storagecompartments.

CAUTIONDo not overfill the engine with oil.Always make sure the oil level iswithin the operating range but notabove the FULL mark.

! WARNINGOverloading this vehicle could resultin loss of control resulting in seriousinjury or death.

Item Specifications(lb) (kg)

Vehicle Load Capacity (Payload) 1500 680

Tongue Weight 150 68Rear Tongue and Cargo Weight (max) 1000 453

Towing Capacity 2000 907

37

Towing Capacity — Total weight oftrailer and all cargo in the trailer.

Trailering and Towing

MOD001B

This vehicle is equipped with a rear frame-mounted receiver for a standard 5.1 cm(2 in.) receiver hitch.

When loading a trailer properly, twoitems are critical: Gross Trailer Weight(the weight of the trailer plus cargo) andTrailer Tongue Weight.

Trailer Tongue Weight is the downwardforce exerted on the hitch by the trailercoupler when the trailer is fully loadedand the coupler is at its normal towingheight. Refer to the Load Capacity Rat-ings Chart for tongue weight information.

Always maintain a slow speed whentrailering and towing and avoid suddenacceleration, quick maneuvers, and sud-den stops. Braking distance will beaffected when towing a trailer. Whentowing a trailer, always maintain slowspeed and allow more stopping distancethan when not towing a trailer.

TransportingWhen transporting, the vehicle must be inits normal operating position (on all fourwheels) and the following procedure mustbe used:

1. Place the transmission in park.

2. Secure the vehicle with load ratedhold-down straps.

MOD156

! WARNINGMake sure that the load in the traileris properly secured and will not shiftwhile moving. Also, do not overloadthe trailer.

! WARNINGNever exceed any of the vehicleweight restrictions.

! WARNINGOperating this vehicle without extracaution when towing a trailer will behazardous. Trailer towing can affectthe handling and braking of the vehi-cle. Tow only at low speeds andnever exceed 10 mph (16 km/h).Avoid sudden acceleration and stop-ping of the vehicle. Do not makequick maneuvers. Avoid uneven sur-faces and do not tow on hills.

! WARNINGNever tow people in or on any deviceexcept when towing a disabled vehi-cle with operable brakes and steeringor on a trailer designed for passen-gers that has a rigid tow bar.

CAUTIONFailure to place the transmission inpark could allow the vehicle to roll offthe trailer in the event of tie-downstrap failure.

38

MOD157A

NOTE: Suitable hold-down strapsare available from an authorizeddealer. Ordinary rope is not recom-mended because it can stretchunder load.

Gas — Oil — LubricantFilling Gas Tank

Since gasoline expands as its temperatureincreases, the gas tank must be filled toits rated capacity only. Expansion roommust be maintained in the tank particu-larly if the tank is filled with cold gaso-line and then moved to a warm area. Allow the engine to cool before filling thegas tank. Care must be taken not to over-fill the tank. If overfilled, gas may leakonto the engine creating a fire hazard.

MOD080A

Tighten the gas tank cap securely afterfilling the tank.

Recommended GasolineThe recommended gasoline to use in thisvehicle is 87 minimum octane regularunleaded. In many areas, oxygenates areadded to the gasoline. Oxygenated gaso-lines containing up to 10% ethanol or 5%methanol are acceptable gasolines.When using ethanol-blended gasoline, it isnot necessary to add a gasoline antifreezesince ethanol will prevent the accumula-tion of moisture in the fuel system.

Recommended Engine Oil

CAUTIONIf using additional hold-down strapsin any other areas, care must betaken not to damage the vehicle.

! WARNINGNever secure a strap across the floor-board of the vehicle.

CAUTIONAlways latch the doors when trans-porting to prevent damage to thedoors and body panels.

! WARNINGAlways fill the gas tank in a well-venti-lated area. Never add gasoline to thegas tank near any open flames or withthe engine running or hot. DO NOTSMOKE while filling the gas tank.

! WARNINGDo not overflow gas when filling thegas tank. A fire hazard could materi-alize. Always allow the engine to coolbefore filling the gas tank.

! WARNINGDo not overfill the tank.

CAUTIONDo not use white gas. Only approvedgasoline additives should be used.

CAUTIONAny oil used in place of the recom-mended oil could cause seriousengine damage. Do not use oils whichcontain graphite or molybdenum addi-tives. These oils can adversely affectclutch operation. Also, not recom-mended are racing, vegetable, non-detergent, and castor-based oils.

39

The recommended oil to use is syntheticengine oil, which has been specificallyformulated for use in the engine. Althoughsynthetic engine oil is the only oil recom-mended for use in this engine, use of anyAPI-certified SM 0W-40 oil is acceptable.

OILCHARTJ

Recommended Transaxle LubricantNOTE: Tracker Off Road recom-mends the use of manufacturer-approved lubricants.The recommended transaxle lubricant is transaxle fluid with EP. This meets all the lubrication requirements of this vehicle.Recommended Front Differential LubricantNOTE: Tracker Off Road recom-mends the use of manufacturer-approved lubricants.The recommended front differentiallubricant is SAE-approved 80W-90 hyp-oid. This meets all the lubricationrequirements of this vehicle.

Engine Break-In After the completion of the break-in period,the engine oil and oil filter should bechanged. Other maintenance after break-inshould include checking of all prescribedadjustments and tightening of all fasteners.At the discretion and expense of the owner/operator, the vehicle may be taken to anauthorized dealer for this initial service.

New vehicles and engines require a “break-in” period. The first month is most criticalto the life of this vehicle. Proper operationduring this break-in period will help ensuremaximum life and performance from thisvehicle.When the engine starts, allow it to warm upproperly. Idle the engine several minutesuntil the engine has reached normal operat-ing temperature. Do not idle the engine forexcessively long periods of time.During the first 2.5 hours of operation,always use less than 40% throttle. For thesecond 2.5 hours of operation, operate at 40-60% with short-term use up to WOT (wide-open throttle). Varying the engine RPMduring the break-in period allows the com-ponents to “load” (aiding the engine/trans-mission component mating process) andthen “unload” (allowing components tocool). Although it is essential to place somestress on the engine components duringbreak-in, care should be taken not to over-load the engine too often.Burnishing Brake PadsBrake pads must be burnished to achieve fullbraking effectiveness. Braking distance willbe extended until brake pads are properly bur-nished.

To properly burnish the brakes, use the fol-lowing procedure:

1. In an appropriate area, accelerate to 30mph (48 km/h); then release the accel-erator pedal and press the brake pedalto decelerate to 0-5 mph (0-8 km/h).

2. Repeat this procedure 20 times.

CAUTIONAny lubricant used in place of the rec-ommended lubricant could cause seri-ous front differential/rear drive damage.

! WARNINGDo not attempt sudden stops or putyourself into a situation where a sud-den stop will be required until thebrake pads are properly burnished.

40

General Maintenance NOTE: Proper maintenance of thisvehicle is important for optimum per-formance. Follow the MaintenanceSchedule and all ensuing mainte-nance instructions/information.If, at any time, abnormal noises, vibrations,or improper functioning of any componentof this vehicle is detected, DO NOT OPER-ATE THE VEHICLE. Take the vehicle toan authorized dealer for inspection andadjustment or repair.

If the owner/operator does not feel qualifiedto perform any of these maintenance proce-dures or checks, take the vehicle to anauthorized dealer for professional service. NOTE: The following instructionsand information refer to specificitems in the maintenance and care ofthis vehicle.

41

* Dealer maintenance

Maintenance SchedulePeriod Check/Inspect Replace Clean

Daily See Pre-Start/Pre-Operation Checklist Break-InFirst10 hours/100 miles (160 km)

-Wheel lug nuts (torque to 100 ft-lb [136 N-m])

First50 hours/500 miles (800 km)

-Wheel lug nuts (torque to 100 ft-lb [136 N-m])-Fluid levels

-Transaxle fluid-Front differential fluid-Engine oil and filter

RecurringEvery100 hours/1000 miles (1600 km)

-Fluid levels-Rear knuckles (grease)-Engine air filter outer element

-Engine air filter outer element, replace as necessary

Every200 hours/2000 miles (3200 km)

-Brake pad wear*-All hardware, tighten if necessary-Battery terminals-Spark arrestor-Drive and driven clutch-Sway bar links and bushings-CVT belt-CVT air inlet-Wheel lug nuts (torque to 100 ft-lb [136 N-m])-Spark plugs, check gap-Clutch engagement RPM (approx. 1200-1300 RPM)-Shocks/springs

-Engine oil and filter-Alternator belt-Spark arrestor, replace as necessary-Drive and driven clutch, replace worn components as necessary-Sway bar links and bushings, replace as necessary-CVT belt, replace as necessary-Spark plugs, replace as necessary

-Radiator-Battery terminals-Spark arrestor-Drive and driven clutch-CVT air inlet-Spark plugs-Drive and driven clutch (blow out with compressed air)-Shocks/springs


-Rubber lines and hoses-Engine air filter inner element-Engine air filter intake hose

-Transaxle fluid-Front differential fluid-Rubber lines and hoses, replace as necessary-Engine air filter inner element, replace as necessary

-Engine air filter intake hose


-Valve lash clearance*

Every24 months

-Brake fluid-Engine coolant

42

Liquid Cooling SystemNOTE: Debris in the engine com-partment or packed between the cool-ing fins of the radiator can reducecooling capability. Using a gardenhose, wash the radiator to removeany debris preventing air flow.

The cooling system capacity can be foundin the specification chart. The cooling sys-tem should be inspected daily for leakageand damage. If leakage or damage isdetected, take the vehicle to an authorizeddealer for service. Also, the coolant levelshould be checked periodically.

NOTE: High engine RPM, low vehi-cle speed, or heavy load can raiseengine temperature. Decreasingengine RPM, reducing load, andselecting an appropriate transmis-sion gear can lower the temperature.

When filling the cooling system, use acoolant/water mixture of 60/40 or a cool-ant/water mixture which will satisfy thecoldest anticipated weather conditions ofthe area in accordance with the coolantmanufacturer’s recommendations. Always maintain the coolant level at thecold fill line of the coolant reservoir.

Checking Coolant1. Lift the hood by turning the 1/4-turn

fasteners located at the rear of thehood. Remove the hood by sliding ittoward the rear of the vehicle and outof the slots in the grill.

MOD044A

2. Inspect the coolant level cold. Thelevel shouldn’t be lower than the coldfull line. When it’s at operating tem-perature, the coolant level may beabove the cold full line.

MOD043

NOTE: If you cannot see anycoolant in the reservoir, inspect thecooling system for leaks. If no leaksare present, add coolant using thebleed procedure below. If a coolantleak is suspected, schedule ser-vice with an authorized dealer.

Bleeding Cooling SystemWhile the cooling system is being filled,air pockets may develop; therefore, makesure the cooling system is properly bled,with no trapped air in the system.

1. Slowly remove the plug from the topof the thermostat housing on the leftside of the engine allowing trappedair to escape.

CAUTIONDo not use a pressure washer toclean the radiator core. The pressuremay bend or flatten the fins causingrestricted air flow, and electrical com-ponents on the radiator could bedamaged. Use only a garden hosewith spray nozzle at normal tap pres-sure.

CAUTIONContinued operation of the vehiclewith high engine temperature mayresult in engine damage or prematurewear.

! WARNINGNever check the coolant level whenthe engine is hot or the cooling sys-tem is under pressure.

43

2. When pure coolant (no air) flowsfrom the bleed hole, install the bleedplug and tighten securely.

3. Fill the cooling system to the cold fillline of the reservoir. Run the enginefor five minutes after the initial fill;then shut off the engine and recheckcoolant level once cool.

MOD152A

NOTE: Use a good quality, biode-gradable glycol-based, automotive-type antifreeze.

Shock AbsorbersEach shock absorber should be visiblychecked weekly for excessive fluid leak-age (some seal leakage may be observedbut it does not indicate the shock is inneed of replacement), cracks or breaks inthe lower case, or a bent shock rod. If anyone of these conditions is detected,replacement is necessary.NOTE: When the vehicle isoperated in extremely coldweather (-23° C/-10° F or colder),a small amount of leakage may bepresent. Unless the leakage isexcessive, replacement is notnecessary.This vehicle is equipped with adjustableshock absorbers in the front and rear toallow for different driving and loadingconditions.

The front shock absorbers or front andrear shock absorbers have an adjustmentsleeve with five preload adjustment posi-tions that can be turned with a specialspanner wrench to increase or decreasecoil spring tension.NOTE: The softest setting is asshown.

MOD186

NOTE: Before attempting toadjust suspension, clean dirt anddebris from the sleeve and removeload from the suspension. Using asuitable lift or jack, lift the vehicleenough to allow the shock assem-bly to fully extend. Use the spannerwrench to adjust the sleeve to thedesired position.To adjust the spring force on these shockabsorbers, rotate the preload adjustmentsleeve with a suitable spanner wrenchuntil desired spring tension is achieved.

CAUTIONAfter operating the vehicle for the ini-tial 5-10 minutes, stop the engine,allow the engine to cool down, andcheck the coolant level. Add coolantas necessary.

Position Spring Force Setting Load

1

Stronger

Soft

Stiff

Light

Heavy

2

3

4

5

44

MOD178

MOD179

MOD180

MOD181

General LubricationCablesNone of the cables require lubrication;however, it is advisable to lubricate theends of the cables periodically with agood cable lubricant.

Cargo Box LatchesPeriodically apply a light coat of greaseto the latches and pins. Do not overgrease.Engine Oil and Filter NOTE: Refer to the recommendedoil viscosity chart on page 40 in thismanual for the proper engine oil.

NOTE: Refer to the oil level stickon page 37 in this manual for thelocation and proper way to check oil.Change the engine oil and oil filter at thescheduled intervals. The engine shouldalways be warm when the oil is changedso the oil will drain easily and completely.

1. Park the vehicle on level ground.2. Remove the middle seat; then remove

the maintenance cover to access theoil filter.

MOD105

3. Tilt the cargo box to the dump posi-tion; then loosen the oil fill cap. Becareful not to allow contaminants toenter the opening.

MOD064

4. Remove the drain plug from the bot-tom of the engine and drain the oilinto a drain pan.

45

MOD020A

5. Using the oil filter wrench and aratchet handle (or a socket or box-endwrench), remove the old oil filter anddispose of properly. Capture oil in asuitable pan or absorbent material.Do not reuse oil filter.

MOD106

NOTE: Clean up any excess oilafter removing the filter.

6. Apply oil to the new filter O-ring andcheck to make sure it is positioned cor-rectly; then install the new oil filter andtighten to 14.8-18.4 ft-lb (20-25 N-m).

7. Install the engine drain plug andtighten to 36.9 ft-lb (50 N-m). Pourthe recommended oil into the fillerhole. Install oil fill cap.

8. Start the engine (while the vehicle isoutside on level ground) and allow itto idle for a few minutes.

9. Turn the engine off and wait approxi-mately one minute. Recheck the oillevel.

10. Inspect the area around the drain plugand oil filter for leaks.

11. Install the maintenance cover andmiddle seat.

12. Check to make sure the oil fill cap issecure and the oil level stick isinstalled correctly; then lower thecargo box to its locked down position.

Front Differential/Transaxle Lubricant (Inspecting/Changing)Inspect and change the lubricant in eachaccording to the Maintenance Schedule.When changing the lubricant, use theappropriate lubricant and use the follow-ing procedure:

1. Place the vehicle on level ground;then remove the fill plugs: (A) frontdifferential and (C) transaxle.

MOD073A

MOD058A

MOD126A

2. Drain the oil into a drain pan byremoving the drain plugs: (E) right-side front differential and (D) tran-saxle.

46

MOD073A

MOD058A

3. After the oil has been drained, installthe drain plugs and tighten to 45 in.-lb(5 N-m) (front differential) and 16 ft-lb (21.8 N-m) (transaxle).

4. Pour recommended quantity and typeof oil into each fill hole:• (A) Front differential fill plug: Add

lube until it is level with (B) fill levelplug.

• (C) Transaxle fill and fill level plug:Add lube until it is level with the bot-tom of (C).

5. Install the fill plugs and tighten to 16ft-lb (21.8 N-m).

Hydraulic Brake

Brake Fluid

MOD705

1. Check the brake fluid level in thebrake fluid reservoir. The fluid levelmust be maintained between theMAX and MIN level marks. If thelevel in the reservoir is low, add DOT4 brake fluid.

NOTE: The brake fluid reservoiris located under the hood.

2. Press the brake pedal several times tocheck for firmness.

3. If the pedal is not firm, take the vehi-cle to an authorized dealer.

Brake HosesCarefully inspect the hydraulic brake hosesfor cracks or other damage. If found, takethe vehicle to an authorized dealer to havethe brake hoses replaced.Brake PadsThe clearance between the brake padsand brake discs is adjusted automaticallyas the brake pads wear. The only mainte-nance that is required is replacement ofthe brake pads when they show excessivewear. Check the thickness of each of thebrake pads as follows:

1. Remove a front wheel.2. Measure the thickness of each brake

pad.

CAUTIONInspect the oil for any signs of metal fil-ings or water. If found, take the vehicleto an authorized dealer for servicing.

! WARNINGBe sure to inspect the hydraulicbrake system before each use.Always maintain brakes according tothe Maintenance Schedule.

FRONT

CAUTIONBe careful not to spill any fluid whenfilling the brake fluid reservoir. Wipeaway spilled fluid immediately.

47

3. If thickness of either brake pad fric-tion material is less than 0.5 mm(0.019 in.), take the vehicle to anauthorized dealer to have brake padsreplaced.

MOD081A

4. Install the wheel and tighten thewheel nuts in 25 ft-lb (34 N-m) incre-ments to a final torque of 100 ft-lb(136 N-m).

NOTE: Whenever the wheels areremoved and installed onto the huband the lug nuts are tightened, referto the Maintenance Schedule foundon page 42 to identify the appropri-ate service interval requiring thetightening of the lug nuts.

Fuel HosesInspect the fuel hoses. Damage fromaging may not always be visible.

Protective Rubber BootsThe protective boots should be inspectedperiodically according to the Mainte-nance Schedule.Ball Joint Boots (Upper and Lower/Right and Left)

MOD094A

1. Secure the vehicle on a support standto elevate the front wheels.

2. Remove both front wheels.3. Inspect the four ball joint boots for

cracks, tears, or perforations.4. Check the ball joint for free-play by

grasping the steering knuckle andturning it from side to side and upand down.

5. If boot damage is present or balljoint free-play seems excessive, con-tact an authorized dealer for service.

Tie Rod Boots (Inner and Outer/Right and Left)

MOD071B

1. Secure the vehicle on a support standto elevate the front wheels.

2. Remove both front wheels.3. Inspect the four tie rod boots for

cracks, tears, or perforations.4. Check the tie rod end free-play by

grasping the tie rod near the end andattempting to move it up and down.

5. If boot damage is present or tie rodend free-play seems excessive, con-tact an authorized dealer for service.

Drive Axle Boots

CC793

1. Inspect all drive axle boots forcracks, tears, or perforations.

48

2. If boot damage is present, contact anauthorized dealer for service.

Rear Knuckle Grease ZerksThere are four grease Zerk fittings on thevehicle — two on each rear knuckle.They can be accessed from the rear of thevehicle.

MOD176

Inspect and add grease in each Zerkaccording to the Maintenance Schedule.

1. Clean any dirt or debris from the Zerkbefore adding grease.

2. Add grease to the Zerk until anytrapped air or moisture is pushed out.

NOTE: Under normal use 2-3pumps of the grease gun is all thatwill be needed.

NOTE: Adding more grease thanneeded may damage the seals.Adding grease until clean grease isvisible is not necessary.

3. Wipe any excess grease from theZerks and seals to prevent dirt anddebris from accumulating.

BatteryThe battery is located in a compartmentin front of the right-rear wheel.After being in service, batteries requireregular cleaning and recharging in order todeliver peak performance and maximumservice life. The following procedures arerecommended for cleaning and maintain-ing lead-acid batteries. Always read andfollow instructions provided with batterychargers and battery products.

NOTE: Refer to all warnings andcautions provided with the batteryor battery maintainer/charger.Loss of battery charge may be caused byambient temperature, ignition OFF currentdraw, corroded terminals, self discharge,frequent start/stops, and short engine runtimes. Frequent winch usage, snowplow-ing, extended low RPM operation, shorttrips, and high amperage accessory usageare also reasons for battery discharge.Maintenance Charging

NOTE: The manufacturer recom-mends the use of the CTEK Multi US800 or the CTEK Multi US 3300 forbattery maintenance charging. Main-tenance charging is required on allbatteries not used for more than twoweeks or as required by batterydrain.

1. When charging a battery in the vehi-cle, be sure the ignition switch is inthe OFF position.

NOTE: Be sure to maintain thefluid of the battery at the UPPERLEVEL. Use only distilled waterwhen adding fluid to these batteries.

2. Clean the battery terminals with asolution of baking soda and water.

3. Be sure the charger and battery are ina well-ventilated area and ensure thebattery charger cables will not contactany battery acid. Be sure the chargeris unplugged from the 110-volt elec-trical outlet.

4. Connect the red terminal lead fromthe charger to the positive terminal ofthe battery; then connect the blackterminal lead of the charger to thenegative terminal of the battery.

NOTE: Optional battery chargingadapters are available from anauthorized dealer to connect directlyto your vehicle from the recom-mended chargers to simplify themaintenance charging process.Check with an authorized dealer forproper installation of these chargingadapter connectors.

49

5. Plug the battery charger into a 110-volt electrical outlet.

6. If using the CTEK Multi US 800,there are no buttons to push. If usingthe CTEK Multi US 3300, press theMode button (A) on the left side ofthe charger until the MaintenanceCharge Icon (B) at the bottom illumi-nates. The Normal Charge Indicator(C) should illuminate on the upperportion of the battery charger.

800D

NOTE: The maintainer/charger willcharge the battery to 95% capacity atwhich time the Maintenance ChargeIndicator (D) will illuminate and themaintainer/charger will change topulse/float maintenance. If the batteryfalls below 12.9 DC volts, the chargerwill automatically start again at thefirst step of the charge sequence.

3300D

NOTE: Not using a battery char-ger with the proper float mainte-nance will damage the battery ifconnected over extended periods.Charging

NOTE: The manufacturer recom-mends the use of the CTEK Multi US800 or the CTEK Multi US 3300 forbattery maintenance charging.

1. Be sure the battery and terminalshave been cleaned with a baking sodaand water solution.

2. Be sure the charger and battery are ina well-ventilated area and ensure thebattery charger cables will not contactany battery acid. Be sure the chargeris unplugged from the 110-volt elec-trical outlet.

3. Connect the red terminal lead fromthe charger to the positive terminal ofthe battery; then connect the blackterminal lead of the charger to thenegative terminal of the battery.

4. Plug the charger into a 110-volt elec-trical outlet.

5. By pushing the Mode button (A) on theleft side of the charger, select the Nor-mal Charge Icon (E). The NormalCharge Indicator (C) should illuminateon the upper left portion of the charger.

6. The battery will charge to 95% of itscapacity at which time the MaintenanceCharge Indicator (D) will illuminate.

NOTE: For optimal charge and per-formance, leave the charger con-nected to the battery for a minimum 1hour after the Maintenance ChargeIndicator (D) illuminates. If the bat-tery becomes hot to the touch, stopcharging. Resume after it has cooled.

7. Once the battery has reached fullcharge, unplug the charger from the110-volt electrical outlet.

NOTE: If, after charging, the bat-tery does not perform to operatorexpectations, bring the battery toan authorized dealer for furthertroubleshooting.

50

Jump-Starting NOTE: DO NOT jump-start a vehiclewith a dead battery. Instead, remove thebattery, service it, and correctly chargeit. In an emergency, however, it may benecessary to jump-start a vehicle. If so,use the following procedure to care-fully and safely complete this proce-dure.

1. On the vehicle to be jump-started,remove the battery cover and any ter-minal boots.

2. Inspect the battery for any signs ofelectrolyte leaks, loose terminals, orbulging sides. Leaking or bulging bat-tery cases may indicate a frozen orshorted battery.

3. Inspect the vehicle to be used for thejump-start to determine if voltage andground polarity are compatible. Thevehicle must have a 12-volt DC, neg-ative ground electrical system.

4. Move the vehicle to be used for thejump-start close enough to ensure thejumper cables easily reach; then shiftinto neutral, set and lock the brakes,shut off all electrical accessories, andturn the ignition switch OFF.

NOTE: Make sure all switches onthe vehicle to be jump-started areturned OFF.

5. Disconnect all external accessoriessuch as cell phones, GPS units, andradios on both vehicles.

6. Attach one clamp of the positive (red)jumper cable to the positive (+) termi-nal (1) of the dead battery (C) beingcareful not to touch any metal withthe other clamp; then attach the otherclamp of the positive (red) jumpercable to the positive (+) terminal (2)of the good battery (B).

! WARNINGImproper handling or connecting of abattery may result in serious injuryincluding acid burns, electrical burns,or blindness as a result of an explosion.Always remove rings and watches.

! WARNINGAny time service is performed on a bat-tery, the following must be observed:keep sparks, open flame, cigarettes, orany other flame away. Always wearsafety glasses. Protect skin and cloth-ing when handling a battery. When ser-vicing a battery in enclosed space,keep the area well-ventilated. Makesure battery venting is not obstructed.

! WARNINGIf any of these conditions exist, DONOT attempt a jump-start, boost, orcharge the battery. An explosion couldoccur causing serious injury or death.

CAUTIONAlways make sure the electrical sys-tems are of the same voltage andground polarity prior to connectingjumper cables. If not, severe electri-cal damage could occur.

CAUTIONFailure to disconnect electronic acces-sories during jump-starting may causesystem damage due to power spikes.

51

0744-527

NOTE: Some jumper cables maybe the same color but the clamps orends will be color-coded red andblack.

7. Attach one clamp of the negative(black) jumper cable to the negative (-)terminal (3) of the good battery (B);then attach the other clamp of the neg-ative (black) jumper cable (4) to anunpainted metal surface (A) on theengine or frame well away from thedead battery and fuel system compo-nents.

8. Stand well away from the dead bat-tery and start the vehicle with thegood battery. Allow the vehicle to runfor several minutes applying somecharge to the dead battery.

9. Start the vehicle with the dead bat-tery and allow it to run for severalminutes before disconnecting thejumper cables.

10. Remove the jumper cables in oppo-site order of hook-up (4, 3, 2, 1). Becareful not to short cables againstbare metal.

NOTE: Have the battery and elec-trical system checked prior to oper-ating the vehicle again.

Spark Plug(s)This vehicle comes equipped with a speci-fied spark plug. See the Specificationschart for the correct spark plug. A lightbrown insulator indicates that the plug iscorrect. A white or dark insulator indicatesthat the engine may need to be serviced.Consult an authorized dealer if the pluginsulator is not a light brown color. To helpprevent cold weather fouling, make sure tothoroughly warm up the engine beforeoperating.To maintain a hot, strong spark, keep theplug free of carbon.

ATV-0051

Before removing the spark plug, be sureto clean the area around the spark plug. Ifyou do not, dirt could enter the enginewhen removing or installing the sparkplug.Adjust the spark plug gap (see Specifica-tions chart) for proper ignition. Use afeeler gauge to check the gap.

ATV-0052

Tighten spark plug to 14.75 ft-lb (20 N-m).

CVT Air InletThis vehicle is equipped with an air inletto collect air for the Continuously Vari-able Transmission (CVT).

! WARNINGNever make the final connection to abattery as a spark could ignite hydro-gen gases causing an explosion ofthe battery resulting in acid burns orblindness.

52

NOTE: When servicing clutchesor belt, it is recommended toinspect and clean the CVT air inlet.

1. Remove the left access panel; loosenthe clamp that holds the snorkel por-tion to the air inlet.

MOD205

2. Disconnect snorkel portion from airinlet; clean and inspect.

3. Install the snorkel to the air inlet andtighten the clamp securely. Reinstallthe left access panel.

Primary Air Filter/Safety Filter/Clean-out ValveThe engine air filter inside the air filterhousing must be kept clean to providegood engine power and fuel mileage. Ifthe vehicle is used under normal condi-tions, service the filter at the intervalsspecified. If operated in dusty, wet, ormuddy conditions, inspect and servicethe filter more frequently. Use the follow-ing procedure to clear the clean-outvalve, remove the primary filter andsafety filter, and inspect and/or cleanthem.

NOTE: To access the air filterhousing, the right side accesspanel must be removed and thecargo box raised if desired.

Air Filter Removal and Inspection

1. Remove dirt and debris from aroundthe air filter housing cover; thensqueeze the clean-out valve to clear itof any accumulated dirt or dust.

2. Check the clean-out valve for cracksor damage. Replace as needed.

MOD085

3. Pull out on the orange air filter hous-ing cover lock; then turn the air filterhousing cover counterclockwise toaccess the filter.

MOD084A

MOD084B

4. Remove the primary air filter ele-ment; then wipe the inside of thehousing to remove dirt and debris.

CAUTIONFailure to inspect the air filter fre-quently if the vehicle is used in dusty,wet, or muddy conditions can dam-age the engine.

53

MOD086

MOD087

5. Inspect the primary air filter elementfor damage or dirt. If damaged the fil-ter must be replaced.

6. A dust trail anywhere inside of the airfilter housing, inlet tube or on thesafety filter is a telltale sign of a leak.Leaks should be inspected by anauthorized dealer.

MOD088

MOD089

7. Remove and inspect the safety filter.

MOD090

Air Filter Installation1. Install safety filter; then install the

primary filter.NOTE: The flower shape of theprimary filter element must line upwith the same-shaped void in theair filter housing for the air filterhousing cover to fit properly.

MOD091A

CAUTIONDo not attempt to clean the primaryfilter or filter damage may occur.

CAUTIONWhen replacing the primary filter,always inspect the new filter for dam-age. Never install a damaged filter. Donot wipe the new filter as it is lubri-cated for sealing purposes.

54

MOD092

2. Install the air filter housing coverwith the clean-out valve at the 5o’clock position; then turn the air fil-ter housing cover clockwise until itseats.

NOTE: The clean-out valveshould be near the 6 o’clock posi-tion when the cover is seated.

3. Lock the air filter housing cover.

MOD084C

MOD084A

4. Install the right access panel andsecure with two 1/4-turn fasteners.

MOD247

Tires

Tire Tread Condition

0732-649

The use of worn-out tires on this vehicleis very dangerous. A tire is considered tobe worn out when the depth of the treadis less than 3 mm (1/8 in.). Be sure toreplace the tires before reaching this min-imum specification.

CAUTIONA torn air filter can cause damage tothe engine. Dirt and dust may getinside the engine if the element is torn.Carefully examine the element for tearsbefore and after cleaning it. Replacethe element with a new one if it is torn.

! WARNINGAlways use the size and type of tiresas specified. Refer to the specifica-tions chart for proper tire inflationpressure, and always maintain propertire inflation pressure.

! WARNINGThe use of worn-out tires is danger-ous and can increase the risk of anaccident.

55

Tire ReplacementThis vehicle has low-pressure tubeless tires.Air is sealed by the contact surfaces of theinner wheel rim and the tire bead. If eitherthe inner wheel rim or tire bead is damaged,air may leak. Be extremely careful not todamage these areas when replacing tires.It is very important to use the propertools when repairing or replacing tires toprevent damage to the tire bead or wheelrims. If proper tools and related items arenot available, have this maintenance per-formed by a qualified tire repair station.

Tubeless Tire RepairShould a leak or flat tire occur due to a punc-ture, the tire may be repaired using a plug-type repair. If the damage is from a cut or ifthe puncture cannot be repaired using a plug,the tire must be replaced. When operatingthe vehicle in areas where transportation orservice facilities are not readily available, itis strongly recommended to carry a plug-type repair kit and a tire pump.

Wheels1. Park the vehicle on level ground and

place the gear selector in park.2. Loosen the lug nuts on the wheel to

be removed.3. Elevate the vehicle.4. Remove the lug nuts.5. Remove the wheel.6. Install the wheel and install the lug

nuts.7. Install the wheel and tighten the

wheel nuts in 25 ft-lb (34 N-m) incre-ments to a final torque of 100 ft-lb(136 N-m).

8. Remove the jack.NOTE: Whenever the wheels areremoved and installed onto the huband the lug nuts are tightened, referto the Maintenance Schedule foundon page 42 to identify the appropri-ate service interval requiring thetightening of the lug nuts.

Muffler/Spark ArresterThe muffler has a spark arrester which mustbe periodically cleaned. At the intervalsshown in the Maintenance Schedule, clean thespark arrester using the following procedure:

1. Remove the cap screw securing thespark arrester assembly to the muffler.

MOD095A

2. Using a suitable brush, clean the car-bon deposits from the screen takingcare not to damage the screen.

NOTE: If the screen or gasket isdamaged in any way, it must bereplaced.

3. Install the spark arrester assemblyand secure with the cap screw.Tighten to 60 in.-lb (6.8 N-m).

CAUTIONWhen breaking the tire bead loosefrom the wheel, be extremely carefulnot to damage the inner wheel sur-face or the tire bead.

! WARNINGUse only manufacturer-approvedtires when replacing tires. Failure todo so could result in unstable opera-tion.

! WARNINGWait until the muffler cools to avoidburns.

56

Light Bulb Replacement

NOTE: The bulb portion of theheadlight is fragile. HANDLE WITHCARE. When replacing the head-light bulb, do not touch the glassportion of the bulb. If the glass istouched, it must be cleaned with adry cloth before installing. Skin oilresidue on the bulb will shorten thelife of the bulb.To replace the headlight bulb, use the fol-lowing procedure:

1. Disconnect the wiring harness; thenremove the rubber boot from the lightassembly.

MOD046

MOD096

2. Remove the old H4 bulb by unlock-ing the spring; then insert the newbulb into headlight assembly and lockthe spring to secure the bulb.

MOD097A

3. Install the rubber boot making sure itis sealed around the bulb and connectthe wire harness.

MOD098A

4. Adjust the headlight (see Checking/Adjusting Headlight Aim in this sub-section).

Taillight/Brake Light AssemblyIf one or more individual LED bulbs arenot working, the taillight/brake lightassembly must be replaced.

MOD096

To replace the taillight/brake light assem-bly, use the following procedure:

CAUTIONUse only specified bulbs indicated inthe Specifications chart as replace-ment bulbs.

CAUTIONWhen replacing the headlight bulb,be careful not to touch the glass por-tion of the bulb. Grasp the new bulbwith a clean rubber gloves.

57

1. Remove the four screws from theinner cargo box side panel, two reartie-down screws and one tailgatelatch bail screw; then remove the sixscrews from the underside of thecargo box and remove the outer cargobox side panel.

MOD114A

MOD115A

2. Remove screw (A); then flex thecargo box fender away from the cargobox to access and remove screw (B).

NOTE: A long extension with asocket or long screwdriver will beneeded to access screw (B).

MOD117A

MOD113

3. Remove the taillight/brake lightassembly and disconnect it from theharness by pushing on the connectorlock.

MOD110

MOD112A

4. Install the new assembly making sureto connect the harness.

MOD112

5. Install screw (A) first; then flex thecargo box fender away from the cargobox to access and install screw (B).

58

MOD117A

MOD113

6. Position the outer cargo box side panelbehind the two tabs on the cargo boxfender; then fit all tabs into theiradjoining slots in the side panel

MOD116A

7. With a suitable pry bar, lift up on theouter cargo box floor near the rearcorner.

MOD110A

8. Start at the rear of the cargo box andtuck the outer side panel under thecargo box and work it into place fromback to front.

MOD111

9. Once the outer side panel is in place,install the screws securing the cargobox fender and outer side panel.

MOD114A

MOD115A

Checking/Adjusting Headlight AimThe headlights can be adjusted vertically.The geometric center of the HIGH beamlight zone is to be used for aiming.

1. Position the vehicle on a level floorso the headlights are approximately6.1 m (20 ft) from an aiming surface(wall or similar aiming surface).

59

MOD038

NOTE: There should be an aver-age operating load on the vehiclewhen adjusting the headlight aim.

2. Measure the distance from the floorto the midpoint of each headlight.

3. Using the measurements obtained instep 2, make horizontal marks on theaiming surface directly in front of theheadlights.

4. Make vertical marks which intersectthe horizontal marks on the aimingsurface directly in front of the head-lights.

5. Switch on the lights. Make sure theHIGH beam is on. DO NOT USELOW BEAM.

6. Observe each headlight beam aim.Proper aim is when the most intensebeam is centered on the vertical mark5 cm (2 in.) below the horizontalmark on the aiming surface.

7. With a 10 mm wrench, turn the head-light adjuster clockwise to adjust thebeam down or counterclockwise toadjust the beam up.

MOD046A

FusesThe fuses are located in two Power Dis-tribution Modules (PDM) under thehood. If there is any type of electricalsystem failure, always check the fusesfirst.

MOD044B

NOTE: To remove the fuse, com-press the locking tabs on eitherside of the fuse cover and lift out.

6411-493

6411-361

NOTE: Spare fuses are locatedinside the fuse cover.

Electrical Output TerminalsThree output terminals for electricalaccessories are located on the front andrear wiring harnesses. Two accessoryplugs are located on the dashboard.

CAUTIONAlways replace a blown fuse with afuse of the same type and rating. Ifthe new fuse blows after a shortperiod of use, consult an authorizeddealer immediately.

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NOTE: The front output terminalsare located behind the LCD infor-mation gauge. The rear output ter-minal is located beneath cargo box.

MOD099A1

Switched Accessory PowerSwitched power is battery power, turnedon by the ignition switch, either in therun or start position. Battery power is ter-minated when the ignition switch isturned off. One switched power outputterminal is located under the dashboardbehind the LCD information gauge.Orange/black is positive and black isnegative. Switched power is ideal foraccessories the operator wants on anytime the ignition key is in the run posi-tion.

Constant Accessory PowerConstant power is direct battery power.Battery power can only be terminated byremoving the 30-amp main fuse. Oneconstant power output terminal is locatedunder the dashboard behind the LCDinformation gauge and one constantpower output terminal is located beneaththe cargo box on the passenger side. Red/white is positive and black is negative.Constant power is ideal for accessoriesthe operator wants to control with acces-sory on/off switches when needed.

MOD100A

MOD101A

Storage Compartments/ToolsThis vehicle has a storage compartmentwithin the dashboard and a tool storagecompartment beneath the hood. To accessthe compartment located under the hood,turn the two 1/4-turn fasteners at the rearof the hood and tilt the hood forward;then slide the hood toward the rear of thevehicle.A basic tool kit is provided in the tool stor-age compartment. Maintain the tool kit withthe vehicle at all times.

MOD044A

CAUTIONAlways use electrical accessoriesless than 30 amps (Accessory Fuse).

FRONT

REAR

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MOD103A

To open the dashboard storage compart-ment, lift up on the lock arm and opentoward the vehicle occupant.

MOD044A

Seat BeltsInspect the seat belts for damage, and frayedor torn edges. Check that the belts extend andretract smoothly and fully without binding orcatching. Check that the latch plate lockssecurely in the buckle and releases when thebutton is depressed. Ensure retractors are freeof dirt and/or debris. Do not grease or oil theretractors.

DoorsInspect the doors and latches for corro-sion, loose hardware and damage.

Occupant Shoulder RestraintsInspect the occupant shoulder restraintsfor damage or loose hardware.

MOD009B1

ROPSInspect the Rollover Protection Structure(ROPS) for any deformation, damage,improper installation, loose or missingfasteners, modifications, drilling, repair,welding and/or a missing label. If any ofthese circumstances are discovered, donot operate and immediately bring thevehicle to an authorized dealer for ser-vice.

! WARNINGIf the seat belt(s) are damaged, frayed,or torn, belt(s) must be replaced.

! WARNINGDo not remove the doors. Removingthe doors increases the risk of seri-ous injury or death.

! WARNINGDo not remove the occupant shoulderrestraints. Removing the shoulderrestraints increases the risk of seri-ous injury or death.

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Preparation for StorageUse the following procedure to prepare thevehicle for storage:

1. Clean the seat cushions with a dampcloth and allow to dry.

2. Clean the vehicle thoroughly by washingdirt, oil, grass, and other foreign matterfrom the entire vehicle. Allow the vehi-cle to dry thoroughly. DO NOT get waterinto any part of the engine or air intake.

3. Either drain the gas tank or add a fuelstabilizer to the gas in the gas tank.

4. Clean the interior of the air filter housing.5. Plug the hole in the exhaust system with

a clean cloth.6. Apply light oil to the upper steering

shaft bushing and plungers of the shockabsorbers.

7. Tighten all nuts, bolts, cap screws, andscrews. Make sure rivets holding com-ponents together are tight. Replace allloose rivets. Care must be taken that allcalibrated nuts, cap screws, and boltsare tightened to specifications.

8. Fill the cooling system to the cold fillline with properly mixed coolant.

9. Disconnect the battery cables (negativecable first); then remove the battery,clean the battery posts and cables, andstore in a clean, dry area.

NOTE: For storage, use a batterymaintainer or make sure the battery isfully charged (see Battery section in thismanual).10. Store the vehicle indoors in a level position.

Preparation after Storage Taking this vehicle out of storage and cor-rectly preparing it will ensure many milesand hours of trouble-free riding. The manu-facturer recommends the following proce-dure:

1. Clean the vehicle thoroughly.2. Clean the engine. Remove the cloth

from the exhaust system.3. Check all control wires and cables for

signs of wear or fraying. Replace if nec-essary.

4. Change the engine/transmission oil andfilter.

5. Check the coolant level and add prop-erly mixed coolant as necessary.

6. Charge the battery; then install. Con-nect the battery cables making sure toconnect the positive cable first.

7. Check the entire brake systems (fluidlevel, pads, etc.), all controls, headlights,taillight, brake light, and headlight aim;adjust or replace if necessary.

8. Check the tire pressure. Inflate to rec-ommended pressure as necessary.

9. Tighten all nuts, bolts, cap screws, andscrews making sure all calibrated nuts,cap screws, and bolts are tightened tospecifications.

10. Make sure the steering moves freelyand does not bind.

11. Check the spark plug. Clean or replaceas necessary.

12. Check the air filter and the air filter hous-ing. Clean or replace as necessary.

CAUTIONPrior to storing this vehicle, it must beproperly serviced to prevent rustingand component deterioration.

CAUTIONAvoid storing outside in direct sunlight andavoid using a plastic cover as moisture willcollect on the vehicle causing rusting.

CAUTIONBefore installing the battery, make sure theignition switch is in the OFF position.

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Warranty Procedure/Owner ResponsibilityAt the time of sale, an ROV Rider Training Certificate and Owner Registration form is to becompleted by the selling dealer and consumer. The receipt of the form by Tracker Off Road is acondition precedent to warranty coverage. It is the selling dealer’s responsibility to retain and/orsubmit appropriate copies of the form to the appropriate place(s) to initiate warranty coverage.The dealer will furnish to the consumer a signed copy of the form which must be presented tothe dealer when requesting warranty service. The registration form is the consumer’s proof ofownership and warranty eligibility. The form is used by the dealer to validate the warranty claim.Retain your copy of the form and keep it in a safe place.When warranty repair is suspected, the ROV should be taken to the selling dealer, who has theprimary responsibility to perform warranty repairs. Subject to the limitations set forth in the Lim-ited Warranty, in the event the selling dealer has ceased to do business, you have moved, oryou are in a location away from your selling dealer, warranty may be performed by any autho-rized Tracker Off Road dealer.The authorized Tracker Off Road ROV dealer will examine the ROV or part to determine if, inhis opinion, a warrantable condition exists. If a warrantable condition appears to exist, thedealer will repair or replace, at Tracker Off Road’s option, free of charge, including any relatedlabor costs, all parts that are found to be warrantable and any other parts which the warrantablepart caused to be damaged. You, the owner, will then be asked to sign a warranty form toensure Tracker Off Road that the warranty work was actually performed.It is the owner’s responsibility to maintain and service the ROV in accordance with Tracker OffRoad’s recommendations in the Operator’s Manual. To protect yourself and your ROV, followall safety and service tips. Tracker Off Road will NOT warrant repairs required as a result of notperforming standard operator maintenance, storage procedures, and service as outlined in theOperator’s Manual.Should you have any questions concerning the warranty, contact an authorized Tracker OffRoad ROV dealer.

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U.S. EPA Emission ControlStatement/Warranty Coverage — ROV

(U.S. Only)

STATEMENT/WARRANTYTracker Off Road warrants to the original retail purchaser, and each subsequent purchaser, that all U.S.EPA-certified Tracker Off Road ROVs are designed, built, and equipped to conform to all U.S. EPAEmission Control Regulations. Please read the following information completely.

An authorized dealer will repair or replace any defective emission-related component at no cost to youduring the warranty period. You may have non-warranty service performed by any repair establishmentthat uses equivalent components. The regulations provide significant civil penalties for tampering thatcauses your ROV to no longer meet U.S. EPA emission standards.

Tracker Off Road further warrants that the engine and its emission-related components are free fromdefects in materials or workmanship that could cause the engine to fail to comply with applicableregulations during the warranty period.

If you have any questions about this information, or the emission warranty coverage statement, contactan authorized dealer.

WARRANTY PERIODThe emission warranty period for this ROV begins on the same date as the standard warrantycoverage and continues for 30 months or 3100 miles, whichever comes first.

COMPONENTS COVERED

The emissions warranty covers major emissions control components and emission-relatedcomponents listed as follows:

Engine Management and Sensors Fuel/Air SystemBarometric Pressure Sensor Fuel InjectorsCamshaft Position Sensor Fuel Pressure RegulatorEngine Control Module (ECM) Fuel PumpEngine Coolant Temperature Sensor Intake Air Temperature SensorManifold Absolute Pressure Sensor Air Bypass ValveOxygen Sensor Crankcase Ventilation SystemThrottle Position Sensor ISC ValveCrankshaft Position SensorExhaust Temperature Sensor

Ignition System Miscellaneous Items Used in Ignition Coil Aforementioned SystemsKnock Sensor System ConnectorsSpark Plugs SwitchesCapacitive Discharge Ignition (CDI) Module GrommetsMagneto Pick-Up Clamps

HosesTiesGasketsWiring

OWNER’S RESPONSIBILITIESThe owner of any ROV warranted under this Emission Control Statement is responsible for the propermaintenance and use of the ROV as stated in the Operator's Manual. Proper maintenance generallyincludes replacement and service, at the owner's choosing, such items as air filter, oil and oil filter, orany other part, item, or device related to emissions control as specified in the Operator's Manual. It isthe owner's responsibility to ensure that the ROV is used in a manner for which it was designed.

For U.S. EPA Emission Control Warranty coverage questions, contact Tracker OffRoad at 877-394-6727.

65

California Emission ControlStatement/Warranty Coverage — OHRV

(U.S. Only)

STATEMENT/WARRANTYThe California Air Resources Board is pleased to explain the emission control system warranty on yourOHRV. In California, new off-highway recreational vehicles must be designated, built and equipped tomeet the State's stringent anti-smog standards. Tracker Off Road must warrant the emission controlsystem on your OHRV for the periods of time listed below provided there has been no abuse, neglector improper maintenance of your OHRV.

Your emission control system may include parts such as the carburetor or fuel-injection system, fueltank, fuel hoses, carbon canister, and engine computer. Also included may be hoses, belts, connectorsand other emission-related assemblies. Where a warrantable condition exists, Tracker Off Road willrepair your OHRV at no cost to you including diagnosis, parts and labor.

WARRANTY PERIODFor 30 months, or 2500 miles, or 250 hours, whichever comes first, except for evaporative componentsover the OHRV high-priced warranty value, which are covered for 60 months, or 5000 miles, or 500hours, whichever comes first.

If any emission-related part on your OHRV is defective, the part will be repaired or replaced by TrackerOff Road.

OWNER’S RESPONSIBILITIESAs the OHRV owner, you are responsible for the performance of the required maintenance listed inyour owner's manual. Tracker Off Road recommends that you retain all receipts covering maintenanceon your OHRV, but Tracker Off Road cannot deny warranty solely for the lack of receipts or for yourfailure to ensure the performance of a scheduled maintenance.

As an owner you are responsible for presenting your OHRV to a Tracker Off Road dealer as soon as aproblem exists. The warranty repairs should be completed in a reasonable amount of time, not toexceed 30 days.

As an OHRV owner, you should also be aware that Tracker Off Road may deny you warranty coverageif your OHRV or a part has failed due to abuse, neglect, improper maintenance or unapprovedmodifications.

If you have any questions regarding your warranty rights and responsibilities, you should contact Tracker OffRoad at 877-394-6727 or the California Air Resources Board at 9528 Telstar Avenue, El Monte, CA 91731.

66

Maintenance RecordDATE MILEAGE SERVICE PERFORMED/NOTES

67

Maintenance RecordDATE MILEAGE SERVICE PERFORMED/NOTES

68

Change of Address, Ownership, or Warranty Transfer

Tracker Off Road keeps on file the current name and address of theowner of this vehicle. This allows us to reach the current owner withany important safety information which may be necessary to protectcustomers from personal injury or property damage. Please make surea copy of this form is completed and returned to us if you move or if thevehicle is sold to another party.

This form may also be used to transfer the unused portion of theoriginal warranty to a second party. In order to transfer warranty, fill outthis form completely; then return a copy of this form to us. We will thenprocess the application and issue warranty for the balance of the timeremaining of the original warranty. Warranty coverage is only availablein the country in which the original retail purchase occurs to the originalretail purchaser resident in that country or to a transferee resident inthat country of the balance of the remaining warranty.

Address ChangeOwnership Change

Warranty Transfer

CHANGE OF ADDRESS/OWNERSHIP/WARRANTY TRANSFER TO:

Name _________________________________________Address _______________________________________City/State (Province) _____________________________Zip Code (Postal Code)____________________________Phone ( ) ____________________________________Email _________________________________________Year and Model _________________________________Vehicle Identification Number (VIN) __________________

69

Fold Back

CHANGE OF ADDRESS/OWNERSHIP

TRACKER OFF ROAD1451 MARVIN GRIFFIN RDAUGUSTA GA 30906-3852 USA

PlaceStampHere

Identification Numbers RecordThis vehicle has two identification numbers: Vehicle Identification Number (VIN)and Engine Serial Number (ESN). These numbers are required by the dealer to com-plete warranty claims properly. No warranty will be allowed if the VIN or ESN isremoved or mutilated in any way.Always provide the name, VIN, and ESN when contacting an authorized dealer forparts, service, accessories, or warranty. If a complete engine must be replaced, ask thedealer to notify the manufacturer for correct registration information.Record the Vehicle Identification Number and Engine Serial Number in the spacesprovided to assist you in ordering parts from an authorized dealer or for reference incase this vehicle is stolen.

1. KEY IDENTIFICATION NUMBER:

The key identification number is stampedon the key. Record this number in thespace provided for reference if you everneed a new key.

2. VEHICLE IDENTIFICATION NUMBER:

The VIN is located on the operator sideof the vehicle, on the frame support railbelow the back of the cargo box abovethe rear shock.

3. ENGINE SERIAL NUMBER:

The ESN is located above the engine oilfilter.

MOD254

MOD187

MOD182

MANUFACTURER INFORMATION:Textron Specialized Vehicles, Inc.1451 Marvin Griffin RoadAugusta, Georgia 30906-3852 USADealer: 800-296-4804Consumer: 877-394-6727www.trackeroffroad.com

*REPLACE

*REPLACE

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NOTES

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operator’s manual · go at a speed which is proper for the terrain, visibility con-ditions, and...

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