Tracker 600 - Throttle Cable Free-Play

70
5. Remove the throttle cable (C) from the actuator arm
by loosening the outer jam nut securing the throttle
cable to the throttle body; then route the cable out of
the way.
6. Remove the TMAP sensor connector (D), fuel injec-
tor connector (E), ISC connector (F), and TPS con-
nector (G).
OHA077
7. Remove the two screws securing the air filter hous-
ing, located in the glove box. Pull the air inlet duct
(A) off the air filter housing (B). Remove clamp
holding boot (C) to throttle body and move the hous-
ing and boot forward to slide boot off throttle body.
NOTE: Moving the air filter housing and boot for-
ward will create clearance to remove the throttle
body.
OHA120
8. Loosen the clamp securing the throttle body to the
intake pipe; then slide the throttle body off the intake
pipe.
9. Use tape to cover and seal the intake opening.
INSTALLING
1. Install the throttle body into the intake pipe and
secure with the clamp. Tighten securely.
2. Install the air filter housing boot and secure with the
two hose clamps.
3. Connect the four electrical connectors to the throttle
body components.
4. Connect the throttle cable to the throttle body and
adjust throttle cable free-play (see Throttle Cable
Free-Play in this section); then connect the gasline
hose.
5. Install the actuator cover to the throttle body and
secure with the two screws.
NOTE: The longer screw goes on top.
6. Connect the battery (positive cable first); then install
the side panels and seat making sure the seat locks
securely into place.
NOTE: If the throttle body, ECM, TPS, or ISC are
replaced, the EFI system must be synchronized. Use
the following procedure:
1. With the key off, depress the throttle lever to Wide
Open Throttle (WOT).
2. Place the ignition key in the ON position and wait for
10 seconds.
3. Release the throttle lever and wait an additional 10
seconds.
4. Turn the key to the OFF position and allow the gauge
to shut off.
Throttle Cable Free-Play
To adjust the throttle cable free-play, follow this proce-
dure.
1. Slide the rubber boot away; then loosen the jam nut
from the throttle cable adjuster.
CF297C
2. Turn the adjuster until the throttle cable has proper
free-play of 3-6 mm (1/8-1/4 in) at the lever.
3. Tighten the jam nut against the throttle cable adjuster
securely; then slide the rubber boot over the adjuster.
CAUTION
Any objects or liquid entering the intake opening will
fall into the engine causing severe damage if the engine
is turned over or started.
B
C
G
D
E
F
E
A