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Tracker Off-Road 800SX Service Manual

Tracker Off-Road 800SX
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800SX
SERVICE MANUAL
p/n: 2263-005
9/20

Table of Contents

Questions and Answers:

Tracker Off-Road 800SX Specifications

General IconGeneral
BrandTracker Off-Road
Model800SX
CategoryOffroad Vehicle
LanguageEnglish

Summary

Torque Specifications

Periodic Maintenance and Tune-Up

Engine Air Filter Service

Procedure for removing, inspecting, and cleaning the engine air filter.

Valve Clearance Checking

Detailed steps for checking valve clearance using a feeler gauge.

Spark Plug Service

Guide for checking, adjusting, and replacing spark plugs.

Engine Oil and Filter Change

Steps for changing the engine oil and oil filter.

Brake System Service and Troubleshooting

Hydraulic Brake System - Checking and Bleeding

Procedure for checking brake fluid level and bleeding the hydraulic system.

Brake Pad Checking and Replacement

How to check brake pad thickness and replace worn pads.

Drive Belt Service

Drive Belt Removal

Step-by-step instructions for removing the drive belt.

Drive Belt Inspection and Installation

Procedures for inspecting and installing the drive belt correctly.

Steering System Service

Electronic Power Steering (EPS) Assembly Removal

Step-by-step guide for removing the EPS assembly.

EPS Assembly Installation

Instructions for installing the steering shaft and EPS assembly.

Rack and Pinion Steering System Service

Procedures for inspecting and installing the rack and pinion steering assembly.

Engine Service Procedures

Removing Engine

General steps for removing the engine from the chassis.

Valve Cover Service

Procedures for removing and installing the valve cover.

Camshaft Drive Belt Service

Procedure for removing and installing the camshaft drive belt.

Adjusting Valve Clearance

Steps for adjusting valve clearance using shims.

Flywheel Service

Procedures for removing, inspecting, and installing the flywheel.

Engine Block and Components Service

Procedures for servicing the oil pan and oil pump.

Installing Engine

Provides instructions for installing the engine into the chassis.

Troubleshooting Engine Performance

Engine Starting Problems

Conditions and remedies for engine starting issues (compression, spark, fuel).

Engine Noise Issues

Conditions and remedies for engine noise from valves, pistons, or crankshaft.

Electrical System Service

Fuel Pump/Fuel Level Sensor Service

Procedures for testing and replacing fuel pump and level sensor.

Starter Motor Service

Procedures for removing, installing, and testing the starter motor.

Starter Relay Service

Procedures for testing the starter relay.

Drive System Service

Front Differential Removal

Procedure for removing the front differential assembly.

Backlash Adjustment

Instructions for setting backlash for proper gear operation.

Transaxle Removal

Procedure for removing the transaxle assembly.

Troubleshooting - System Issues

Drive System Troubleshooting

Conditions and remedies for drive system power transmission and gear noise issues.

Brake System Troubleshooting

Conditions and remedies for poor braking, excessive pedal travel, leaks, and spongy pedal.

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