Tracker Off-Road XTR1000 User manual

XTR1000
SERVICE MANUAL
p/n: 2262-827
7/19

1
Table of Contents
General Information/Foreword ......................................... 2
Specifications ............................................................... 2
Torque Specifications ................................................... 3
Torque Conversions (ft-lb/N-m) .................................... 4
Drive Belt Break-In Procedure...................................... 4
Gasoline — Oil — Lubricant ......................................... 4
Preparation for Storage ................................................ 5
Preparation after Storage ............................................. 6
Periodic Maintenance/Tune-Up ........................................ 7
Air Filter ........................................................................ 7
Spark Arrester .............................................................. 8
Valve/Tappet Clearance ............................................... 8
Testing Engine Compression........................................ 8
Spark Plugs .................................................................. 9
Engine Oil — Filter ....................................................... 9
Front Differential — Transaxle Lubricant/Fluid ........... 10
Headlight — Taillight — Brake Light........................... 11
Hydraulic Brake System ............................................. 14
Burnishing Brake Pads ............................................... 15
Replacing V-Belt ......................................................... 15
Steering/Body/Controls................................................... 17
Hood/Rear Cargo Tray/Grille ...................................... 17
Body Panels ............................................................... 18
Front Wheel Alignment ............................................... 23
Shift Lever .................................................................. 23
Shift Cable .................................................................. 24
LCD Gauge................................................................. 25
Exhaust System.......................................................... 25
Seats .......................................................................... 27
Deluxe Bimini Top ...................................................... 29
Front Bumper.............................................................. 29
Rear Bumper .............................................................. 29
Troubleshooting .......................................................... 30
Engine............................................................................... 31
Removing Engine ....................................................... 31
Installing Engine ......................................................... 34
Servicing..................................................................... 38
Disassembling ............................................................ 38
Servicing Components ............................................... 43
Assembling ................................................................. 51
Assembly Schematic .................................................. 59
Troubleshooting .......................................................... 61
Servicing Clutch Components .................................... 62
Fuel/Lubrication/Cooling................................................. 69
Gas Tank .................................................................... 69
Oil Pump..................................................................... 70
Fuel Pump...................................................................70
Fuel/Vent Hoses..........................................................70
Liquid Cooling System ................................................70
Radiator.......................................................................71
Thermostat ..................................................................73
Fans ............................................................................73
Water Pump ................................................................74
Troubleshooting ..........................................................76
Electrical System..............................................................77
Battery.........................................................................77
Electronic Power Steering (EPS) ................................78
Ignition Switch .............................................................80
Ignition Coils................................................................80
Accessory Receptacle/Connector ...............................81
Switches......................................................................81
Fan Motors ..................................................................83
Front Drive Actuator ....................................................83
Lights...........................................................................84
Power Distribution Module (PDM)...............................85
EFI Sensors/Components ...........................................86
Starter Motor ...............................................................92
Starter Relay ...............................................................93
Alternator/Regulator/ Rectifier/Stator ..........................93
Electronic Control Module (ECM)................................95
Gauge Diagnostic Menu..............................................96
Diagnostic Trouble Codes (DTC) ................................99
Troubleshooting ........................................................102
Drive and Brake Systems ..............................................103
Front Drive Coupler ...................................................103
Front Differential........................................................106
Drive Axles ................................................................115
Transaxle ..................................................................120
Driveshaft/Carrier Bearing.........................................135
Hydraulic Brake Caliper (Front Shown).....................139
Master Cylinder Assembly.........................................141
Disc Brake.................................................................142
Troubleshooting ........................................................143
Suspension .....................................................................144
Shock Absorbers.......................................................144
Front A-Arms.............................................................145
Rear Trailing Arms ....................................................149
Front Sway Bar .........................................................153
Rear Sway Bar ..........................................................154
Wheels and Tires ......................................................155
Troubleshooting ........................................................155

2
General
Information/Foreword
This Service Manual contains service, maintenance, and
troubleshooting information for the 2020 XTR1000 model.
The complete manual is designed to aid service personnel
in service-oriented applications.
This manual is divided into sections. Each section covers a
specific vehicle component or system and, in addition to
the standard service procedures, includes disassembling,
inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as
to how much disassembly is needed to correct any given
condition.
This service manual is designed primarily for use by a
basic level technician. The procedures found in this man-
ual are of varying difficulty, and certain service proce-
dures in this manual require one or more special tools to
be completed. The technician should use sound judgment
when determining which procedures can be completed
based on their skill level and access to appropriate special
tools.
NOTE: Whenever a part is worn excessively, cracked,
or damaged in any way, replacement is necessary.
When replacement of parts is necessary, use only genuine
parts. They are precision-made to ensure high quality and
correct fit. Refer to the appropriate Illustrated Parts Manual
for the correct part number, quantity, and description.
All publications and decals display the words Warning,
Caution, Note, and At This Point to emphasize important
information. The symbol !WARNING identifies
personal safety-related information. Be sure to follow the
directive because it deals with the possibility of serious
personal injury or even death. A CAUTION identifies
unsafe practices which may result in vehicle-related dam-
age. Follow the directive because it deals with the possi-
bility of damaging part or parts of the vehicle. The
symbol NOTE: identifies supplementary information
worthy of particular attention. The symbol  AT
THIS POINT directs the technician to certain and
specific procedures to promote efficiency and to improve
clarity.
At the time of publication, all information, photographs,
and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes
only and are not designed to depict actual conditions.
Because products are constantly refined and improved,
no retroactive obligation is incurred.
All materials and specifications are subject to change with-
out notice.
Specifications
 NOTE: Specifications subject to change without notice.
* Visible at plug threads.
CHASSIS
Dry Weight (approx) 821 kg (1812 lb)
ROPS Tested Curb Weight 1179.4 kg (2600 lb)
Length (overall) 345.4 cm (136 in.)
Height (overall) 172.7 cm (68 in.)
Width (overall) 162.6 cm (64 in.)
Tire Size 30 x 10-15 — front
30 x 10-15 — rear
Tire Inflation Pressure 14 psi (96.5 kPa) — front
22 psi (151.7 kPa) — rear
MISCELLANEOUS
Spark Plug Type NGK CR9EB
Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.)
Gas Tank Capacity 37.85 L (10 U.S. gal)
Coolant Capacity (60% Antifreeze/40%
Water Mixture)
9.5 L (2.5 U.S. gal)
Front Differential Capacity 400 ml (13.5 fl oz)*
Transaxle Capacity 1.2 L (40.5 fl oz)
Engine Oil Capacity
(Approx. Capacity at oil change)
2.55 L (2.70 U.S. qt)
Compression Ratio 11.3:1
Gasoline (recommended) Regular gas 86 PON, 91 RON or
higher/ethanol content not to
exceed 10%
Engine Oil (recommended) ACX All Weather (Synthetic)
Front Differential Lubricant SAE-Approved 80W-90 Hypoid
Transaxle Lubricant Synthetic Transaxle Fluid with EP
Belt Width 38.4 mm
Brake Fluid DOT 4
Taillight/Brake Light LED
Headlight Halogen H13 with LED
Electric Starter Type Constant Mesh
COOLING SYSTEM
Cooling Fan 1 On 194° F (90° C)
Cooling Fan 1 Off 185° F (85° C)
Cooling Fan 2 On 203° F (95° C)
Cooling Fan 2 Off 194° F (90° C)
Thermostat Opening Temperature 156.2-163.4° F (69-73° C)
ELECTRICAL SYSTEM
Ignition Coil Resistance (primary)
(secondary)
1.40 ohm ± 15%
10,000 ohm ± 15%
Ignition Coil Primary Voltage Battery Voltage
Stator Coil Resistance 0.19 ohm ± 20%
Pickup Coil Resistance 495 ohm ± 20%
AC Magnetos Output 14 volts, 39 A @ 5000 RPM
Alternator Output 65 amps
Ignition Timing 8° BTDC @ 1500 RPM
Intake Air Temperature Sensor 315 ohm @ 176° F (80° C)
Coolant Temperature Sensor 5,740 ohm @32° F (0° C)
310-326 ohm @ 176° F (80° C)
183.6 ohm @ 212° F (100° C)
VALVES AND GUIDES
Valve Head Diameter (intake)
(exhaust)
30.90-31.10 mm
25.90-26.10 mm
Valve/Tappet Clearance (intake)
(cold engine) (max) (exhaust)
0.16 mm
0.22 mm
Valve Guide/Stem (intake)
Clearance (max) (exhaust)
0.08 mm
0.10 mm
Valve Guide Inside Diameter (max) 4.550 mm
Valve Head Thickness (min) 2.3 mm
Valve Seat Angle 45° +15’/+30’
Valve Spring Free Length (min) 37.59 mm
Valve Spring Tension @ 34.6 mm 112.30-129.30 N (25.25-29 lb)

3
Torque Specifications
CYLINDERS, PISTONS, AND RINGS
Piston/Cylinder Clearance
(max)
.035-.060 mm
0.120 mm
Cylinder Bore 80.000-80.010 mm
Piston Diameter 79.950-79.965 mm
Bore x Stroke 80.0 x 66.2 mm
Cylinder Trueness (max) 0.05 mm
Piston Ring End Gap Installed (Top)
(2nd)
(Oil)
.15-.25 mm
.30-.45 mm
.10-.35 mm
Piston Ring Side Clearance Installed (Top)
(2nd)
(Oil)
.030-.065 mm
.020-.055 mm
.040-.140 mm
Piston Ring Groove Width (1st/2nd)
(Oil)
1.202-1.204 mm
2.501-2.503 mm
Piston Ring Thickness (1st/2nd) 1.170-1.195 mm
Piston Pin Bore (max) 19.045 mm
Piston Pin Outside Diameter (min) 18.971 mm
CRANKSHAFT
Connecting Rod (small end diameter)
(big end diameter)
19.005-19.018 mm
41.00-41.018 mm
Crankshaft Runout (max) 0.05 mm
Crankshaft Thrust Clearance 0.05-0.25 mm
Torque (ft-lb) Tolerance
0-15 ±20%
16-39 ±15%
40+ ±10%
Part Part Bolted to Torque
ft-lb N-m
EXHAUST COMPONENTS
Manifold Engine 16 22
Muffler Transaxle Bracket 16 22
Spark Arrester Muffler 72 in-lb. 8
O2 Sensor Manifold 20 27
BRAKE COMPONENTS
Brake Disc Hub 16 22
Brake Hose Caliper 20 27
Brake Hose Master Cylinder 20 27
Brake Hose Frame 8 11
Master Cylinder Frame 25 34
Rear Caliper**** Bearing Housing 35 48
Front Caliper**** Knuckle 35 48
Remove Reservoir Frame 8 11
Front Brakeline Clip Upper A-Arm 6 8
Brake Pedal Frame 18 25
SUSPENSION COMPONENTS (Front)
A-Arm (Upper) Frame 75 102
A-Arm (Lower) Frame 75 102
A-Arm (Upper) Knuckle 75 102
A-Arm (Lower) Knuckle 75 102
Knuckle Tie Rod End 42 57
Shock Absorber**** Frame 75 102
Shock Absorber**** A-Arm 75 102
Knuckle Assembly** Axle 250 339
Sway Bar Mount Frame 42 57
Sway Bar Link A-Arm 35 48
SUSPENSION COMPONENTS (Rear)
Sway Bar Mount Frame 35 48
Sway Bar Sway Bar Link 35 48
Sway Bar Link Trailering Arm 35 48
Trailering Arm Frame 170 230
Bearing Housing Assembly Trailering Arm 35 48
Shock Trailering Arm 65 88
Shock Frame 65 88
Hub** Axle 250 339
Trailering Arm Rod End Trailering Arm 90 122

4
*w/Oil
**w/Red Loctite #271
***w/Green Loctite #270
****w/“Patch-Lock”
*****w/Anti-Seize
Torque Conversions
(ft-lb/N-m)
Drive Belt Break-In
Procedure
New drive belts require a break-in period of 25 miles.
During this period, drive the vehicle for 25 miles at 3/4
throttle or less while varying throttle position (but not
exceeding 40 mph). By varying throttle position, the
exposed cord on the side of a new belt will be condi-
tioned allowing the drive belt to gain its optimum flexi-
bility and will extend drive belt life.
Gasoline — Oil — Lubricant
FILLING GAS TANK
Since gasoline expands as its temperature rises, the gas tank
must be filled to its specified capacity only. Expansion room
must be maintained in the tank particularly if the tank is filled
with cold gasoline and then moved to a warm area.
Part Part Bolted to Torque
ft-lb N-m
STEERING COMPONENTS
Steering Rack Mount Bracket 20 27
Mount Bracket Frame 20 27
EPS Bracket EPS Unit 35 48
Lower Steering Shaft (Splined End) Steering Rack 35 48
Lower Steering Shaft (Adj. Yoke) Self 35 48
Lower Steering Shaft (Upper
Splined End)
EPS Unit 35 48
Upper Steering Shaft (Splined End) EPS Unit 20 27
Upper Steering Shaft (Adj. End) Self 35 48
Tilt Steering Sub Assembly Frame 20 27
Tilt Steering Shock Frame 8 11
Steering Shaft** Steering Wheel 25 34
SEAT BELT ASSEMBLY
Seat Belt Retractor Frame 60 82
Seat Belt Flange Frame 60 82
Seat Belt Buckle Frame 60 82
Seat Belt Rear ROPS 35 48
SHIFTER ASSEMBLY
Shift Knob Shift Lever 12 16
Shift Cable End Shift Lever 8 11
Shift Cable Threads Bracket/Transaxle 20 27
Shift Cable Bracket Transaxle 6 8
Shift Axle Shift Bracket 8 11
COOLING ASSEMBLY
Upper Radiator Bracket Frame 14 19
P-Clamp Frame 8 11
Overflow Bottle Support Bracket 8 11
Lower Radiator Bracket Frame 14 19
Radiator Fan Radiator Shroud 6 8
Shroud Assembly Radiator 8 11
CLUTCH ASSEMBLY
Drive Clutch Engine 60 81
Drive Clutch Fan Drive Clutch 60 in-lb. 7
Cam Arm Drive Clutch 50 in-lb. 6
Spider Stationary Sheave 250 339
Clutch Cover Movable Sheave 120 in-lb. 14
Torque Bracket Movable Sheave 120 in-lb. 14
Driven Clutch Transaxle 60 82
ENGINE/TRANSAXLE COMPONENTS
Engine Cradle Engine 35 48
Engine/Transaxle Mid Mount Cradle 35 48
Engine Mid Mount 65 88
Front Mount Engine Cradle 35 48
Isolator Front Mount 35 48
Isolator Frame/Rear Hanger 35 48
Transaxle Mid Mount 65 88
Mount Bracket Mid Mount 35 48
Transaxle Rear Mount 35 48
Isolator Rear Mount 35 48
Rear Hanger Frame 35 48
FRAME/ROPS COMPONENTS
Rear ROPS Assembly Frame 35 48
Lower Front Skid Frame 65 88
ROPS Frame 35 48
Front ROPS Rear ROPS 35 48
Lower Air Dam Lower Front Skid 8 11
Headlight Mount Frame 8 11
Shift Support Frame 20 27
Tire Hold Down Bracket Frame 20 27
Cargo Mount Frame 8 11
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
11.4 26 35.4 51 69.4 76 103.4
22.7 27 36.7 52 70.7 77 104.7
34.1 28 38.1 53 72.1 78 106.1
45.4 29 39.4 54 73.4 79 107.4
56.8 30 40.8 55 74.8 80 108.8
68.2 31 42.2 56 76.2 81 110.2
79.5 32 43.5 57 77.5 82 111.5
810.9 33 44.9 58 78.9 83 112.9
912.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
! WARNING
Always fill the gas tank in a well-ventilated area. Never
add fuel to the gas tank near any open flames or with
the engine running. DO NOT SMOKE while filling the
gas tank.

5
Tighten the gas tank cap securely after filling the tank.
RECOMMENDED GASOLINE
The recommended gasoline to use in this vehicle is regu-
lar unleaded gasoline with a pump octane number (PON)
of 86 or higher, or research octane number (RON) of 91
or higher. If knocking or pinging occurs, use a different
brand of gasoline or premium unleaded gasoline. Oxy-
genated gasolines containing up to 10% ethanol are
acceptable gasolines. Gasolines containing any amount
of methanol are not recommended.
When using ethanol-blended gasoline, it is not necessary
to add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.
RECOMMENDED ENGINE OIL
The recommended oil to use is ACX All Weather Syn-
thetic engine oil, which has been specifically formulated
for use in this engine. Although ACX All Weather Syn-
thetic engine oil is the only oil recommended for use in
this engine, use of any API-certified SM 0W-40 oil is
acceptable.
OILCHARTJ
RECOMMENDED FRONT
DIFFERENTIAL LUBRICANT
The recommended lubricant is the manufacturer-branded
Gear Lube or an equivalent gear lube which is
SAE-approved 80W-90 hypoid. This lubricant meets all
of the lubrication requirements of the vehicle front differ-
ential.
RECOMMENDED TRANSAXLE
LUBRICANT
The recommended transaxle lubricant is Synthetic Tran-
saxle Fluid with EP. This lubricant meets all of the lubri-
cation requirements of this vehicle.
Preparation for Storage
The manufacturer recommends the following procedure
to prepare the vehicle for storage:
1. Clean the seat cushions with a damp cloth and allow
to dry.
2. Clean the vehicle thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire vehi-
cle. Allow the vehicle to dry thoroughly. DO NOT
get water into any part of the engine or air intake.
3. Either drain the gas tank or add a fuel stabilizer 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 shock absorbers.
7. Tighten all nuts, bolts, cap screws, and screws. Care
must be taken that all calibrated nuts, cap screws,
and bolts are tightened to specifications.
8. Fill the cooling system to the bottom of the stand
pipe in the radiator neck with properly mixed cool-
ant.
9. Disconnect the battery cables (negative cable first);
then remove the battery, clean the battery posts and
cables, and store in a clean, dry area.
NOTE: For storage, use a battery maintainer or
make sure the battery is fully charged (see Battery
section in this manual).
10. Store the vehicle indoors in a level position.
! WARNING
Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the engine to
cool before filling the gas tank.
! WARNING
Do not over-fill the gas tank.
CAUTION
Do not use white gas. Only approved gasoline additives
should be used.
CAUTION
Any lubricant used in place of the recommended lubri-
cant could cause serious front differential damage.
CAUTION
Any lubricant used in place of the recommended lubri-
cant could cause serious transaxle damage.
CAUTION
Prior to storing this vehicle, it must be properly serviced
to prevent rusting and component deterioration.
CAUTION
Avoid storing outside in direct sunlight and avoid using
a plastic cover as moisture will collect on the vehicle
causing rusting.

6
Preparation after Storage
Taking this vehicle out of storage and correctly preparing
it will ensure many miles and hours of trouble-free rid-
ing. The manufacturer 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 necessary.
4. Change the engine oil and filter.
5. Check the coolant level and add properly mixed
coolant as necessary.
6. Charge the battery; then install. Connect the battery
cables making sure to connect the positive cable
first.
7. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brake light,
and headlight aim; adjust or replace if necessary.
8. Check the tire pressure. Inflate to recommended
pressure as necessary.
9. Tighten all nuts, bolts, cap screws, and screws mak-
ing sure all calibrated nuts, cap screws, and bolts are
tightened to specifications.
10. Make sure the steering moves freely and does not
bind.
11. Check the spark plugs. Clean or replace as necessary.
12. Check the air filter and the air filter housing. Clean
or replace as necessary.
CAUTION
Before installing the battery, make sure the ignition
switch is in the OFF position.

7
Periodic
Maintenance/Tune-Up
Tighten all nuts, bolts, and cap screws. Care must be
taken that all calibrated nuts, bolts, and cap screws are
tightened to specifications.
It is advisable to lubricate certain components periodi-
cally to ensure free movement. Apply light oil to the
components using the following list as reference:
A. Accelerator Pedal Pivot/Cable Ends
B. Brake Pedal Pivot
C. Shift Cable
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appro-
priate tool description.
NOTE: When indicated for use, each special tool
will be identified by its specific name, as shown in the
chart below, and capitalized.
NOTE: Special tools are available from the Service
Department.
Air Filter
CLEANING AND INSPECTING FILTER
NOTE: The air filter is located above the engine and
can be accessed by removing the rear cargo tray.
1. Remove dirt and debris from around the filter hous-
ing.
2. Pull the release tab out away from the filter housing.
XX227
3. Rotate the end of the housing approximately 1/16 of
a turn counterclockwise to release the cover from the
air cleaner.
4. Pull the air cleaner element out of the air cleaner.
 NOTE: Once the filter has been removed, lightly
tap the filter to remove any dust particles or contami-
nants from the filter. If the filter is excessively covered
in dust particles and contaminants, it must be
replaced.
XX228
5. Plug the intake tube with a clean shop towel. Then
clean the inside of the air cleaner body.
6. Remove the shop towel from the intake tube. Then
place a new air cleaner element into the filter hous-
ing. Push the element into the housing until it is fully
seated.
Description p/n
Compression Tester Kit Common Tool
Oil Filter Wrench Common Tool
Timing Light Common Tool
CAUTION
Failure to inspect the air filter frequently if the vehicle is
used in dusty, wet, or muddy conditions can damage
the engine.
CAUTION
Do not use compressed air to clean the paper element.
This may cause tears in the element and allow particles
to enter the combustion chamber leading to accelerated
engine wear.

8
XX229
7. Reinstall the air filter cover, then turn it approxi-
mately 1/16 of a turn clockwise to seat it to the hous-
ing. Verify the duck bill drain is located at the bottom
of the assembly. Then lock the cover to the housing
by pressing the retainer tab inward toward the assem-
bly.
8. Install the rear cargo tray.
Spark Arrester
NOTE: The muffler has a spark arrester which
must be periodically cleaned. At the intervals shown
in the Maintenance Schedule, clean the spark arrester
using the following procedure.
1. Remove the screw (A) securing the spark arrester
assembly to the muffler.
XX081
2. Using a suitable brush, clean the carbon deposits
from the screen taking care not to damage the screen.
NOTE: If the screen or gasket is damaged in any
way, it must be replaced.
WC929
3. Install the spark arrester assembly and secure the
screw. Tighten to 72 in.-lb.
Valve/Tappet Clearance
NOTE: To check/adjust clearance, see Engine —
Servicing Components.
Testing Engine
Compression
NOTE: The engine should be warm (operating tem-
perature) and the battery fully charged for an accu-
rate compression test.
NOTE: The rear cargo tray must be removed for
this procedure.
1. Remove spark plugs. See spark plugs section for
proper procedure.
2. Attach the spark plug connectors to the ignition
coils. Attach spark plugs to the ignition coils and
ground the plugs on the cylinder heads well away
from the spark plug holes.
3. Attach the Compression Tester Kit.
4. While holding the throttle in the full-open position,
crank the engine over with the electric starter until
the gauge stops climbing (five to 10 compression
strokes). Compression should be 217-261 psi
(1500-1800 kPa). Verify the cylinder compression
readings are within 10% of each other.
5. If compression is abnormally low, verify the following:
A. Starter cranks engine over (normal speed).
B. Gauge is functioning properly.
C. Throttle in the full-open position.
D. Valve/tappet clearance correct.
E. Engine warmed up.
! Warning
Wait until the muffler cools to avoid burns
CAUTION
Do not ground the spark plug on the cylinder head
cover. The cover is made of magnesium and any contact
with spark or electrical arc will severely pit the surface.

9
6. If compression is still low, check for blown cylinder
head gasket, valve leakage, or worn piston rings or cyl-
inder (see Engine – Servicing Components).
Spark Plugs
NOTE: The rear cargo tray must be removed for
this procedure.
1. Using compressed air, blow any debris from around
the ignition coils. Remove the spark plug connectors
(B) from the ignition coils (A).
XX068
2. Remove bolts from ignition coils (A). Remove igni-
tion coil (A). Remove spark plugs.
A light brown insulator indicates the plug and fuel/air
ratio are correct. A white or dark insulator indicates that
the engine may need to be serviced. To maintain a hot,
strong spark, keep the plug free of carbon. Adjust the gap
to 0.7-0.8 mm (0.028-0.031 in.).
ATV-0051
ATV-0052
A new spark plug should be tightened 1/2 turn once the
washer contacts the cylinder head. A used spark plug
should be tightened 1/8-1/4 turn once the washer contacts
the cylinder head.
Engine Oil — Filter
OIL — FILTER
Change the engine oil and oil filter at the scheduled inter-
vals. The engine should always be warm when the oil is
changed so the oil will drain easily and completely.
NOTE: The rear cargo tray must be removed to
access the oil tank and top of the engine.
1. Park the vehicle on level ground.
2. Loosen the oil level stick. Be careful not to allow
contaminants to enter the opening.
XX230
3. Loosen the fill plug on top of the valve cover. Be
careful not to allow contaminants to enter the open-
ing.
CAUTION
Before removing a spark plug, be sure to clean the area
around the spark plug. Dirt could enter engine when
removing or installing the spark plug.
! WARNING
Always wear safety glasses when using compressed air.

10
XX231
4. Remove the drain plug and crush washer from the
bottom of the oil tank. Use a funnel to direct the oil
into a drain pan.
XX232
5. Remove the drain plug and washer from the bottom
of the engine and drain the oil into a drain pan.
NOTE: There is a “triangle” symbol cast into the oil
pan located next to the drain plug for identification
purposes.
XX033A
6. Using the oil filter wrench and a ratchet handle (or a
socket or box-end wrench), remove the old oil filter
and dispose of properly. Verify the oil filter seal has
been removed along with the filter. Do not re-use oil
filter.
NOTE: Clean up any excess oil after removing the
filter.
7. Apply new engine oil to the new oil filter seal; then
install the new oil filter onto the engine. Tighten
securely.
8. Install the engine drain plug and new washer.
Tighten to 7.2 ft-lb (9.8 N-m). Install the oil tank
drain plug and new washer. then tighten to 12 ft-lb
(16 N-m).
9. Pour 2.70 US qt (2.55 L) of ACX All-Weather syn-
thetic oil into the oil tank. Install the dipstick. Install
the fill plug on top of the valve cover.
10. Start the engine (while the vehicle is outside on level
ground) and allow it to idle until at least one of the
radiator fans cycles on and off. Check for any leak-
ing oil. If oil is leaking, immediately stop the engine
and correct the cause of the leak before proceeding.
NOTE: The manufacturer recommends the use of
genuine lubricants.
NOTE: The oil level stick should NOT be threaded
into the oil tank for checking purposes
11. Turn the engine off and wait approximately one min-
ute. Remove the dipstick from the oil tank and recheck
the oil level. Add more oil if the level is not visible on
the dipstick. The oil level MUST be within the operat-
ing range.
Front Differential —
Transaxle Lubricant/Fluid
To change front differential lubricant, use the following
procedure:
NOTE: The fill plug is located on the front right side
of the differential.
1. Place the vehicle on level ground; then remove the
fill plug.
XX116
2. Drain the lubricant into a drain pan by removing the
drain plug. Clean away any debris that may have
accumulated onto the magnetic end of the plug.

11
XX117
3. After the lubricant has been drained, install the drain
plug and tighten to 10-22 ft-lb (14-30 N-m).
4. Add SAE-approved 80W-90 hypoid gear lube into
the fill plug hole. The lubricant level should be
approximately level with the bottom of the plug
threads.
5. Install the fill plug and tighten to 10-22 ft-lb
(14-30 N-m).
To change transaxle fluid, use the following procedure:
NOTE: The fill plug is located on the front right side
of the transaxle.
NOTE: If the fluid is contaminated with water,
inspect the drain plug, fill plug, and/or bladder.
1. Place the vehicle on level ground; then remove the
fill plug.
XX113
2. Drain the fluid into a drain pan by removing the
drain plug. Clean away any debris that may have
accumulated onto the magnetic end of the plug.
XX114
3. After the fluid has been drained, install the drain
plug and tighten to 10-22 ft-lb (14-30 N-m).
4. Add Synthetic Transaxle Fluid with EP into the fill
plug hole. The fluid level should be approximately
level with the bottom of the plug threads.
5. Install the fill plug and tighten to 10-22 ft-lb (14-30 N-m).
Headlight —
Taillight — Brake Light
HEADLIGHT BULB REPLACEMENT
NOTE: The LED strips in the headlight assembly
are not individually replaceable. The entire assembly
must be replaced as a component.
1. Remove hood
2. Remove the wiring harness connector (A) from the
back of the headlight bulb (B).
3. Rotate the headlight bulb (B) counterclockwise to
remove from the assembly.
XX069
4. Rotate the new headlight bulb (B) clockwise into
headlight assembly. Reinstall wiring harness connec-
tor (A).
5. Adjust the headlight using the Checking/Adjusting
Headlight Aim instructions in this section.

12
REMOVING HEADLIGHT ASSEMBLY
1. Remove hood.
2. Remove the headlight retaining knob.
XX069A
3. Remove the wiring harness connectors. Remove the
retainers on both sides of the headlight assembly that
secure the headlight assembly.
XX070
XX071
4. Headlight assembly mounts in a C-shaped channel.
Slide headlight assembly toward the rear of the vehi-
cle to release from the channel.
5. Remove headlight from rear housing of headlight
assembly by turning counterclockwise.
XX072A
INSTALLING HEADLIGHT ASSEMBLY
1. Install headlight bulb from rear of headlight assem-
bly by turning clockwise.
XX072
2. Headlight assembly mounts in a C-shaped channel.
Slide headlight assembly toward front of vehicle to
mount into C-shaped channel. Install the retainers on
both sides of the headlight assembly that secure the
headlight assembly.
XX070A

13
XX071
3. Install the wiring harness connectors.
XX070B
4. Install the headlight retaining knob.
XX069A
5. Adjust the headlight using the Checking/Adjusting
Headlight Aim instructions in this section.
REMOVING TAILLIGHT/BRAKE LIGHT
NOTE: The LED taillights are not serviceable. The
entire assembly must be replaced as a component.
1. Remove the rear cargo tray.
2. Disconnect the wiring harness connector. Remove
the screws securing the taillight to the fascia.
XX073
INSTALLING TAILLIGHT/BRAKE LIGHT
1. Install screws to the fascia. Connect the wiring har-
ness connector.
XX073
CHECKING/ADJUSTING HEADLIGHT
AIM
The headlights can be adjusted vertically. The geometric
center of the HIGH beam light zone is to be used for ver-
tical aiming.
1. Position the vehicle on a level floor so the headlights
are approximately 6.1 m (20 ft) from an aiming sur-
face (wall or similar aiming surface).
XX029
NOTE: There should be an average operating load
on the vehicle when adjusting the headlight aim.
2. Measure the distance from the floor to the midpoint
of each headlight.

14
3. Using the measurements obtained in step 2, make
horizontal marks on the aiming surface directly in
front of each headlight.
4. Switch on the lights. Make sure the HIGH beam is
on. DO NOT USE LOW BEAM.
5. Observe each headlight beam aim. Proper aim is
when the most intense beam is 5 cm (2 in.) below the
horizontal mark on the aiming surface.
6. Adjust each headlight until correct aim is obtained
by loosening (counterclockwise) the retaining knob;
then pivot the assembly up or down. Once the correct
level is achieved, tighten (clockwise) the retaining
knob.
XX069A
Hydraulic Brake System
CHECKING
The hydraulic brake system has been filled and bled at
the factory. To check hydraulic brake system, use the fol-
lowing procedure.
1. With the vehicle in a level position and the tires
properly inflated, check the fluid level in the reser-
voir. If the level in the reservoir is not above the MIN
line, add DOT 4 brake fluid.
NOTE: The brake fluid reservoir is located under-
neath the hood.
XX022
2. Press the brake pedal several times to check for a
firm brake. If the brake is not firm, the system must
be bled.
BLEEDING
1. To bleed hydraulic brake system, use the following
procedure:
A.Remove the brake fluid reservoir cover and fill
the reservoir with DOT 4 brake fluid.
B. Install and secure the cover; then slowly press the
brake pedal several times.
C. Install one end of a clear hose onto the bleed
screw farthest from the cylinder (right rear) and
direct the other end into a container; then while
holding slight pressure on the brake pedal, open
the bleed screw and watch for air bubbles. Close
the bleed screw before releasing the brake pedal.
Repeat this procedure until no air bubbles are
present.
XX226
NOTE: During the bleeding procedure, watch the
reservoir very closely to make sure there is always a
sufficient amount of brake fluid. If the fluid level gets
low in the reservoir, refill the reservoir before the
bleeding procedure is continued.
D. Repeat step C until the brake pedal is firm.
E. At this point, perform steps B, C, and D on the left
rear bleed screw; then move to the right front
bleed screw and follow the same procedure. Fin-
ish with the left front bleed screw.
2. Carefully check the entire hydraulic brake system to
ensure that all hose connections are tight, the bleed
screws are tight, the protective caps are installed, and
no leakage is present.
INSPECTING HOSES
Carefully inspect the hydraulic brake hoses for cracks or
other damage. If found, the brake hoses must be replaced.
CAUTION
This hydraulic brake system is designed to use DOT 4
brake fluid only. If brake fluid must be added, care must
be taken as brake fluid is very corrosive to painted sur-
faces.

15
CHECKING/REPLACING PADS
The clearance between the brake pads and brake discs is
adjusted automatically as the brake pads wear. The only
maintenance that is required is replacement of the brake
pads when they show excessive wear. Check the thick-
ness of each of the brake pads as follows.
1. Remove a wheel.
2. Measure the thickness of each brake pad.
WT220
3. If thickness of either brake pad is less than 1.0 mm
(0.039 in.), the brake pads must be replaced.
NOTE: The brake pads should be replaced as a set.
4. To replace the brake pads, use the following proce-
dure:
A.Remove the cap screws securing the caliper
holder to the knuckle (front) or the wheel bear-
ing assembly (rear); then remove the pads from
the caliper.
B. Install the new brake pads.
C. Secure the caliper holder to the knuckle with
new “patch-lock” cap screws. Tighten to 35 ft-lb
(48 N-m).
XX225
6. Install the wheel; then using a crisscross pattern,
tighten the wheel nuts in 20 ft-lb (27 N-m) incre-
ments to a final torque of 95 ft-lb (129 N-m).
7. Burnish the brake pads (see Burnishing Brake Pads
in this section).
BRAKE DISC
Using a micrometer, measure the thickness of the brake
disc in the contact surface. If thickness is 0.125-in. or
less, the disc must be replaced. To replace the brake disc,
see Drive and Brake Systems – Disc Brake.
Burnishing Brake Pads
Brake pads must be burnished to achieve full braking
effectiveness. Braking distance will be extended until
brake pads are properly burnished.
1. Choose an area large enough to safely accelerate the
vehicle to 30 mph and to brake to a stop.
2. Accelerate to 30 mph; then release the accelerator
pedal and depress the brake pedal to decelerate to 0-5
mph.
3. Repeat procedure 20 times until brake pads are bur-
nished.
Replacing V-Belt
NOTE: Drive belts require a break-in period (see
Drive Belt Break-In Procedure in the General Infor-
mation/Foreword Section).
REMOVING
1. Loosen the clamp securing the cooling duct to the
CVT cover.
XX140
2. Unlatch the clamps securing the CVT cover.
! WARNING
Failure to properly burnish the brake pads could lead to
premature brake pad wear or brake loss. Brake loss can
result in severe injury or death.
CAUTION
Failure to properly break-in a new drive belt will result in
premature belt failure.

16
XX108
3. Remove the CVT cover. When removing CVT cover,
disconnect from cooling duct.
XX141
4. Install the Belt Removal Tool turning clockwise into
the driven clutch. Remove the drive belt starting
from the bottom of the driven clutch.
XX142
XX143
CHECKING
Use the Drive Belt Gauge to identify any abnormal wear.
Measure across the top of the V-belt (in multiple loca-
tions) using a Vernier caliper. Do not squeeze the belt as
doing so may produce an inaccurate measurement. The
V-belt must be at least 38.4 mm (1.5 in.) at any point.
INSTALLING
1. Install the Belt Removal Tool into the driven clutch
by turning clockwise. Install the drive belt starting
from the bottom of the driven clutch making sure the
directional arrows on the belt are aligned with engine
rotation.
2. Remove the Belt Removal Tool by turning counter-
clockwise from the driven clutch. Place the transmis-
sion in neutral and rotate the driven clutch and drive
belt by hand in a counterclockwise direction until the
drive belt has reached the outermost point of the
driven clutch.
3. Making sure the clutch cover gasket stays within the
channel along the whole CVT cover housing install
the CVT cover from the rear of the vehicle.
4. Latch the clamps securing the CVT cover.
XX108
5. Connect the cooling duct to the CVT cover; then
install and tighten the clamp securing the cooling
duct to the CVT cover.
XX140

17
Steering/Body/Controls
The following steering components should be inspected
periodically to ensure safe and proper operation:
A. Steering wheel secure.
B.Steering has equal and complete full-left and
full-right turning capability.
C. Steering sector mounting bolts tight.
D. Ball joints not worn, cracked, or damaged.
E. Tie rods not bent or cracked.
F. Knuckles not worn, cracked, or damaged.
G. Cotter pins not damaged or missing.
H. Steering wheel tilt locks securely.
The frame and welds should be checked periodically for
damage, bends, cracks, deterioration, broken compo-
nents, and missing components.
Hood/Rear Cargo
Tray/Grille
REMOVING/INSTALLING HOOD
1. Turn the two 1/4-turn fasteners counterclockwise and
remove hood.
VOR-471
2. Insert the tabs on the rear of hood into the rear por-
tion of the front body panels. Lay the hood down flat.
Turn both of the fasteners clockwise securing the
hood.
REMOVING/INSTALLING REAR CARGO
TRAY
1. Remove fasteners from the rear cargo tray by turning
counterclockwise
VOR-474
2. Remove rear cargo tray by lifting vertically.
3. Rear cargo tray is directional. Install the rear cargo
tray.
4. Secure with fasteners by turning clockwise. Tighten
fasteners securely
REMOVING GRILLE
1. Remove hood.
2. Remove fasteners securing lower fascia. Remove
lower fascia.
VOR-472
3. Remove the fasteners securing the grille.
VOR-473
4. Remove grille by slightly lifting fenders while care-
fully sliding grille downward.

18
CLEANING AND INSPECTING GRILLE
Clean any dirt or debris from the grille webbing. This
helps air flow to the radiator.
INSTALLING GRILLE
Place the grille into position and secure it using the exist-
ing cap screws. Tighten all hardware to 60 in.-lb.
Body Panels
REMOVING REAR FASCIA
1. Remove the rear cargo tray.
2. Remove the wire harness connected to the taillights.
Taillight removal is not required to remove rear fas-
cia.
3. Remove the cap screws securing the rear fascia.
Remove rear fascia.
VOR-475
REMOVING REAR FENDERS
1. Remove rear cargo tray.
2. Remove rear fascia.
3. Remove cap screws securing rear upper front fender.
Remove rear upper front fender.
XX085D
XX088
XX087
XX086
4. Remove the cap screws securing the rear upper
fender. Remove rear upper fender.
! WARNING
The heat deflectors under the rear cargo tray have sharp
edges and can cause serious injury if care is not taken.

19
XX085A1
XX089
XX090
5.Remove the cap screws securing the rear lower
fender. When removing right side proceed to step 6.
When removing left side, remove rear lower fender.
XX085B1
XX091
XX092
XX093
6. When removing right rear fenders, loosen the gas
tank filler hose clamp behind the passenger seat.
XX083
7. Remove the panel from the frame while also pulling
on the filler hose. Seal off the hose to prevent objects
from entering the hose.