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Cushman Trackster User Manual

Cushman Trackster
71 pages
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Cushman Trackster Specifications

General IconGeneral
BrandCushman
ModelTrackster
CategoryOffroad Vehicle
LanguageEnglish

Summary

SAFETY SYMBOLS

SPECIFICATIONS

General Safety Warnings

Critical safety notes applicable to maintenance and operation procedures.

TWO-CYCLE ENGINE OPERATION

FACTORS AFFECTING PERFORMANCE

Compression Check Procedure

Instructions on how to perform a compression test on the engine.

ENGINE OVERHAUL AND TUNE-UP

ENGINE DISASSEMBLY

IGNITION TIMING

ENGINE BREAK-IN AND GOVERNOR

Governor System Operation

Details on governor lubrication, belt tension, and linkage adjustments.

TROUBLESHOOTING: ENGINE START ISSUES

Spark Test Procedure

Checking for spark quality at the spark plug leads.

Fuel System Troubleshooting

Diagnosing fuel delivery problems when the engine won't start.

FUEL SYSTEM CLOGGING AND FOULING

Fuel System Clogging Issues

Identifying causes of fuel system blockages and prevention methods.

Excessive Spark Plug Fouling

Common causes and remedies for spark plug fouling.

STARTER SYSTEM TESTING

Starter Circuit Tests

Testing the electrical circuit for the starter motor.

Starter Motor Tests

Performing tests on the starter motor itself for condition.

STARTER MOTOR TESTING

Voltage Drop Test

Method for checking voltage drop in the starter circuit.

No-Load Test

Testing starter speed and current draw without load.

Stalled Torque Test

Testing starter motor torque under load conditions.

STARTER MOTOR INSPECTION

TROUBLESHOOTING THE STARTING SYSTEM

Engine Won't Crank with Electric Starter

Diagnosing issues when the electric starter fails to crank the engine.

Starter Drive Failure Diagnosis

Identifying causes of starter drive mechanism failures.

Engine Won't Crank with Manual Starter

Diagnosing problems when the manual starter does not operate.

Starter Motor Overspeed Damage

Causes and prevention of damage from starter motor overspeed.

POWER UNIT REMOVAL

TRANSMISSION REMOVAL FROM POWER UNIT

TRANSMISSION DISASSEMBLY

Hydrostat Removal Procedure

Steps for safely removing the hydrostat units from the transmission.

TRANSMISSION COMPONENT SERVICE

Pinion Gear Service

Removing pinion gear and adjusting backlash using shims.

HYDROSTAT AND TRANSMISSION INSTALLATION

Aligning and Installing Transmission

Aligning the transmission and installing control rods.

CHECKING HYDROSTAT CONDITION

Hydrostat Performance Test

Performing a test to check for wear in the hydrostat units.

HYDROSTAT REPLACEMENT

AIR LEAKS IN DRIVE SYSTEM

CHECKING AND LOCATING AIR LEAKS

Air Leak Detection Methods

Using oil level changes and inspections to find air leaks.

T-HANDLE ADJUSTMENT

CONTROL ROD ADJUSTMENTS

Neutral Adjustment Procedure

Adjusting control rods to achieve neutral positioning of the T-handle.

Stop Adjustment Procedure

Adjusting control rod travel limits for proper operation.

TRANSMISSION FLUID SERVICE

TOWING INSTRUCTIONS

Hydrostatic Transmission Towing Clips

Using clips to allow movement without engine power.

Towing Safety Warnings

Critical safety precautions to be observed during towing.

AUTOMATIC SPROCKET LOCK INSTALLATION

Sprocket Lock Installation Steps

Detailed steps for installing the automatic sprocket lock system.

Moving Trackster with Engine Stopped

Procedures for moving the vehicle when the engine is not running.

CD IGNITION SYSTEM

TROUBLESHOOTING: CD IGNITION

Spark Discharge Safety Warning

High voltage shock hazard warning during spark checks.

SPARK PLUGS

CHARGING SYSTEM

BATTERY SERVICE AND TESTING

Battery Testing and Charging

Procedures for testing battery charge and performing slow charging.

FUEL RECOMMENDATIONS

Fuel Mixture Ratio Guidelines

Recommended fuel and oil mixture ratios for the Trackster engine.

FUEL SYSTEM OPERATION

Fuel System Clogging Issues

Causes, prevention, and remedies for fuel system blockages.

CARBURETOR SERVICE

Carburetor Function

Explains how the carburetor controls fuel-air mixture.

Carburetor Repair

Detailed steps for cleaning, inspecting, and disassembling the carburetor.

Carburetor Adjustment

Procedure for final adjustment of idle and mixture settings.

TRACK AND BEARING SERVICE

Track Tension Adjustment

Measuring and adjusting track tension for proper operation.

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