Tracker Off-Road TRACKER LX4 Li, Service & Parts Manual

Page 1: ...SERVICE PARTS MANUAL 696883 C Revised 07 19 Issued 04 19...

Page 2: ......

Page 3: ...right to incorporate engineering and design changes to products in this manual without obligation to include these changes on units sold previously The information contained in this manual may be rev...

Page 4: ...ates of America Federal and State emission certification applicable at the time of manufacture BATTERY PROLONGED STORAGE All batteries will self discharge over time The rate of self discharge varies d...

Page 5: ...SERVICE PARTS MANUAL V ACCELERATOR A 1 BATTERY CHARGER B 1 BODY C 1 BRAKES D 1 ELECTRICAL E 1 ELECTRONIC SPEED CONTROL F 1 FRONT SUSPENSION AND STEERING G 1 MOTOR H 1 REAR AXLE J 1 REAR SUSPENSION K 1...

Page 6: ...Page iv NOTES Service Parts Manual Service Parts Manual...

Page 7: ...E MANUAL To use this manual consult the TABLE OF CONTENTS to locate the information or illustration required Introduction of some revisions varies due to supply of components therefore it is possible...

Page 8: ...er is found The part number is the lowest assembly sold by Service Parts and the asterisk indicates that the part depicted is not available for purchase NOTE Descriptions are indented under the assemb...

Page 9: ...mber for the body part will denote the color code locate the part number for the cowl rear body seat pod side panel or seat wrap then locate your color in the list below replace the last or XX with th...

Page 10: ...RATOR 37 Front of Vehicle 32 33 28 22 29 30 22 24 20 15 14 26 25 36 2 3 4 10 11 21 19 18 17 16 4 5 7 8 To harness from direction selector Part of Frame 1 Pedal Box Assembly includes items 2 33 27 Acce...

Page 11: ...Truss Head Screw SS 8 32 x 3 4 Lg 2 6 7 01050G02 Pan Head Torx Screw 4 20 x 5 8 Lg 2 8 28444G01 Accelerator Rod Cam 1 9 10 00983G01 Self Threading Nut 38 2 11 602484 Plunger 1 12 13 14 17677G1 Spring...

Page 12: ...the product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY ACCELERAT...

Page 13: ...Page A 4 696883 Service Parts Manual Notes ACCELERATOR...

Page 14: ...Page B 1 696883 Service Parts Manual BATTERY CHARGER 1 2...

Page 15: ...e product Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page B 2 696...

Page 16: ...Page B 3 696883 Service Parts Manual Notes BATTERY CHARGER...

Page 17: ...Page B 4 696883 Service Parts Manual Notes BATTERY CHARGER...

Page 18: ...Page C 1 696883 Service Parts Manual BODY 5 4 3 2 7 6 1 19 20 12 14 15 21 17 18 13 16 10 11 9 8 Front of Vehicle Front of Vehicle...

Page 19: ...2 4 75048G04 Spacer 328 x 75 x 1 Lg 2 5 75048G02 Spacer 328 x 75 x 1 31 Lg 2 6 00559G8 Flat Washer Narrow 5 16 4 7 00565G8 Lock Washer 5 16 4 8 70452G01 Access Cover 1 9 14601G11 Rivet Aluminum 3 16 x...

Page 20: ...Service Parts Manual BODY 7 Instrument Panel Assembly includes items 8 16 8 Instrument Panel Assembly with Ball Deflector includes items 9 13 22 15 12 13 20 21 23 22 10 11 9 14 16 4 3 6 5 4 2 1 23 Fr...

Page 21: ...3 16 x 1 Lg 6 5 614378 Fender Flare Driver Side 1 6 613274 Fender Flare Passenger Side 1 7 674314 Instrument Panel Assembly Includes Item 8 16 1 8 71917G01 Instrument Panel Assembly with Ball Deflecto...

Page 22: ...Page C 5 696883 Service Parts Manual BODY 2 25 13 12 21 20 1 25 23 24 Front of Vehicle Front of Vehicle 15 18 17 22 6 7 8 9 5 14...

Page 23: ...G6 Hex Head Bolt 5 16 18 x 625 Lg Grade 5 2 7 00559G8 Flat Washer 5 16 2 8 11098G6 Lock Nut 5 16 18 2 9 00715G2 Hex Washer Head Bolt 5 16 18 x 8 Lg 2 10 11 12 635054G02 Fender Liner Passenger Side 1 1...

Page 24: ...Page C 7 696883 Service Parts Manual BODY 1 2 6 7 7 8 10 9 3 Front of Vehicle Rear Bumper Installation 16 14 15 14 17 12 19 Front of Vehicle 4...

Page 25: ...72G1XX Rear Body With Taillights 1 See HOW TO USE Section for COLOR CODES 2 10570G10 Rivet SS 5 32 x 9 16 Lg 2 3 10570G12 Rivet Aluminum 257 x 556 Lg 2 4 633917 Rivet Plastic 2 5 6 71320G01 Access Pan...

Page 26: ...Page C 9 696883 Service Parts Manual BODY 2 3 3 6 4 1 5 3 Front of Vehicle Frame...

Page 27: ...dual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page C 10 696883 Service Parts Manual BODY 1 698122 Weight Mounting Bracket 1...

Page 28: ...Page C 11 696883 Service Parts Manual Notes BODY...

Page 29: ...Page C 12 696883 Service Parts Manual Notes BODY...

Page 30: ...696883 Service Parts Manual Page D 1 BRAKES 28 19 21 3 10 11 12 24 26 18 21 22 23 17 20 25 14 9 13 5 6 7 16 15 27 2 WHITE BLACK 1 Brake Pedal Assembly With Brake Lights includes items 2 28...

Page 31: ...7 16409G1 Oval Rivet 3 8 x 15 32 Lg 9 8 9 652820 Service Brake Pedal Plate 1 10 70682G01 Pivot Pin 1 11 70681G01 Torsion Spring 408 Dia x 93 Lg 2 12 658825 Push Nut 5 16 2 13 00737G8 Flat Head Phillip...

Page 32: ...D 3 BRAKES Part of Frame Accelerator Pedal 1 12 21 29 30 13 47 48 2 15 17 17 27 28 18 19 18 19 16 16 20 24 25 26 31 3 4 5 49 11 36 37 40 43 41 42 40 44 46 39 38 45 Compensator Assembly includes items...

Page 33: ...Hex Washer Head Bolt 1 4 20 x 7 Lg Not Illustrated 1 7 12416G2 Nylon Wedge Lock Clamp Not Illustrated 3 8 9 10 11 01111G01 Retaining Ring SS Dia 8 4 12 10386G3 Clevis Pin 438 x 938 Lg 1 13 10387G3 Cot...

Page 34: ...levis Pin 438 x 938 Lg 1 33 10387G3 Cotter Pin 094 x 75 Lg 1 34 35 36 654663 Compensator Assembly Includes Items 37 49 1 37 00532G4 Hex Nut 1 4 20 2 38 629486 Spherical Hex Nut 5 16 24 1 39 28082G01 E...

Page 35: ...Page D 6 Notes BRAKES 696883 Service Parts Manual...

Page 36: ...S Front of Vehicle 4 26 25 10 18 17 1 2 16 Brake Assembly Driver Side includes items 3 9 Brake Assembly Passenger Side includes items 3 8 10 Brake Drum Assembly includes items 17 18 22 5 21 24 23 3 8...

Page 37: ...ng 1 4 612412 Brake Shoe Trailing 1 5 612413 Dust Cover 1 6 612415 Brake Spring Top 1 7 612414 Brake Spring Bottom 1 8 612416 Shoe Clamp 2 9 612418 Gear Adjuster Driver Side 1 10 612417 Gear Adjuster...

Page 38: ...Page D 9 Notes BRAKES 696883 Service Parts Manual...

Page 39: ...Page D 10 Notes BRAKES 696883 Service Parts Manual...

Page 40: ...Page E 1 696883 Service Parts Manual ELECTRICAL Note FRAME SHOWN PARTIALLY 1...

Page 41: ...es a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page E 2 696883 Service Parts...

Page 42: ...Page E 3 696883 Service Parts Manual ELECTRICAL ADVANCED BATTERY 2 MODULE Front of Vehicle Frame 1 10 15 10 16 14 17 17 15 15 10 11 9 6 8 12 11 11 12 9 2 6 7 11 12 9 4 3 2...

Page 43: ...665953 Battery Management System 1 2 665954 Cell Module 2 3 663490 Battery Tray 1 4 651809 Bottom Tray 1 5 6 01101G01 Tie Down Bolt 2 7 654002G01 Hold Down Bracket Driver Side 1 8 654002G02 Hold Down...

Page 44: ...Page E 5 696883 Service Parts Manual ELECTRICAL 6 3 10 7 9 5 1 2 11 4 8 10 Front of Vehicle Battery Pack ADVANCED BATTERY 2 MODULE 13 14...

Page 45: ...ce Parts Manual ELECTRICAL 1 651878 Top Cover 1 2 654616 Button Head Tapping Screw 10 X 625 Lg 5 3 652090 Harness BMS to Main Harness 1 4 654863 Flanged Hex Head Bolt 1 4 10 x 8 3 4 Lg 2 5 651960 Batt...

Page 46: ...Manual ELECTRICAL Front of Vehicle To Battery Rear Fender 5 6 8 9 10 7 DC DC Converter Assembly includes items 5 7 4 1 2 Front of Vehicle Seat Wrap 17 13 15 21 12 Control Panel Assembly includes items...

Page 47: ...5 DC DC Converter 1 6 633303 DC DC Converter Bracket 1 7 632372 Self Tapping Screw 10 32 x 3 4 Lg 4 8 00414G6 Hex Head Bolt 1 4 20 x 3 4 Lg Grade 5 2 9 00559G7 Flat Washer 1 4 2 10 11027G2 Flanged Loc...

Page 48: ...assenger Side includes item 3 2 8 LED Headlight Assembly Driver Side includes item 3 1 10 Rear Body 24 25 19 26 27 20 Taillight Assembly Front of Vehicle Taillight Assembly Driver Side includes items...

Page 49: ...ing Nut 5mm x 10mm x 15mm 4 7 71781G02 Vinyl Tape 1 8 619100 Headlight Bulb 1 9 10 677730 Jumper Harness Hi Low Led Headlight 1 11 12 664780 Jumper Harness Turn Signal Lights Not Illustrated 1 13 6966...

Page 50: ...Page E 11 696883 Service Parts Manual Notes ELECTRICAL...

Page 51: ...Page E 12 696883 Service Parts Manual Notes ELECTRICAL...

Page 52: ...Page F 1 696883 Service Parts Manual ELECTRONIC SPEED CONTROL Front of Vehicle Part of Solenoid 3 9 3 4 5 5 10 16 16 17 6 2 7 8 14 14 11 12 15 18 13 8 4 1 Controller Assembly includes items 2 13...

Page 53: ...0G01 Flat Washer 1 4 2 4 11027G2 Flanged Lock Nut 1 4 20 2 5 00414G5 Hex Head Bolt 1 4 20 x 1 2 Lg Grade 5 2 6 663609G06 Controller Bracket Front 1 7 663609G08 Controller Bracket Rear 1 8 606264 Flang...

Page 54: ...Page F 3 696883 Service Parts Manual Notes ELECTRONIC SPEED CONTROL...

Page 55: ...Page F 4 696883 Service Parts Manual Notes ELECTRONIC SPEED CONTROL...

Page 56: ...Tie Rod Not Shown for Clarity Part of Frame Part of Frame 2 13 14 2 13 20 Spindle and Hub Assembly Passenger Side includes items 3 12 Spindle and Hub Assembly Driver Side includes items 4 12 14 21 25...

Page 57: ...bly 2 6 74332G01 Wheel Hub 1 7 36038G01 Drive Flange Stud 4 8 12093G1 Castle Nut 1 14 1 9 00798G8 Cotter Pin 5 32 x 1 3 4 Lg 1 10 632925 Flanged Bushing 1 11 632926 Bushing Sleeve 1 12 51141G1 Race Be...

Page 58: ...al FRONT SUSPENSION AND STEERING Front of Vehicle 19 5 Steering Column Assembly includes items 6 16 19 Tie Rod Assembly includes items 20 24 32 6 9 3 3 3 4 15 14 12 11 10 13 17 8 7 28 27 38 39 40 23 2...

Page 59: ...Steering Column Bushing 1 9 70580G01 Intermediate Shaft 1 10 01055G01 Hex Head Bolt M8 1 25 x 1 18 Lg Grade 5 1 11 00565G8 Lock Washer 5 16 1 12 70751G01 Retaining Ring Internal 1 13 70888G01 Retainin...

Page 60: ...hat is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY FRONT SUSPENSION AND STEERING 32 71147G01 Ste...

Page 61: ...Page G 6 696883 Service Parts Manual Notes FRONT SUSPENSION AND STEERING...

Page 62: ...G 7 696883 Service Parts Manual FRONT SUSPENSION AND STEERING Rack and Pinion Unit includes items 2 23 1 Tie Rod End Outer includes items 24 25 23 16 15 14 13 12 5 6 7 8 9 19 2 20 11 4 18 10 21 17 24...

Page 63: ...2 20 1 5 70750G01 Retaining Ring External 1 6 15112G1 Ball Bearing 1 7 70603G01 Pinion 1 8 70751G01 Retaining Ring Internal 1 9 70638G01 Seal Pinion 1 10 70604G01 Steering Rack 1 11 Set Screw 10 32 x...

Page 64: ...Page G 9 696883 Service Parts Manual Notes FRONT SUSPENSION AND STEERING...

Page 65: ...Page G 10 696883 Service Parts Manual Notes FRONT SUSPENSION AND STEERING...

Page 66: ...Page H 1 696883 Service Parts Manual MOTOR Axle Assembly Front of Vehicle 5 2 4 1 6 8 7...

Page 67: ...ual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page H 2 696883 Service Parts Manual MOTOR 1 680638 Motor 48V AC 1 2 605714 Fle...

Page 68: ...Page H 3 696883 Service Parts Manual Notes MOTOR...

Page 69: ...Page H 4 696883 Service Parts Manual Notes MOTOR...

Page 70: ...1 696883 Service Parts Manual REAR AXLE 24 12 13 10 23 11 17 21 29 20 31 8 30 22 19 37 18 37 9 33 4 25 9 14 29 32 19 37 18 37 36 35 34 28 35 36 17 Front of Vehicle 1 Rear Axle 16 99 1 includes items...

Page 71: ...ntial Assembly 1 5 6 7 8 15558G1 Flanged Hex Head Cover Bolt 5 16 18 x 75 Lg 10 9 17473G1 Bearing Assembly 2 10 23519G2 Ball Bearing Single Lip Seal 1 11 23520G1 Ball Bearing 1 12 23530G1 Retainer Rin...

Page 72: ...roduct Indicates a component that is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY REAR AXLE 32 62...

Page 73: ...Page J 4 696883 Service Parts Manual Notes REAR AXLE...

Page 74: ...696883 Service Parts Manual Page K 1 REAR SUSPENSION 4 3 3 2 2 1 12 13 12 16 12 12 13 17 15 10 9 8 7 11 9 3 2 4 5 2 3 18 19 6 Front of Vehicle 20...

Page 75: ...sher I D 406 x O D 1 25 4 3 10194G1 Rubber Bushing 4 4 00532G6 Hex Nut 3 8 24 2 5 10044G01 Vinyl Cap 1 6 667990 Leaf Spring 2 7 624030 Flanged Bushing 2 8 652708G03 Lift Bracket 1 9 00560G1 Flat Washe...

Page 76: ...Page K 3 Notes REAR SUSPENSION 696883 Service Parts Manual...

Page 77: ...Page K 4 Notes REAR SUSPENSION 696883 Service Parts Manual...

Page 78: ...1 35 34 33 36 36 37 38 Seat Back Assembly includes items 2 9 1 Seat Back Assembly includes items 5 9 4 Seat Bottom Assembly includes items 17 26 16 Flip Seat Bottom Assembly includes items 31 38 30 Se...

Page 79: ...9 2 5 71752G01 Cover Plastic 1 6 71754G01 Padding Foam 1 7 645021 Base Assembly 1 8 01107G01 Pan Head Torx Screw 8 x 63 Lg 4 9 71753G02 Vinyl Cover Gray 1 10 01006G01 Hex Washer Head Thread Forming S...

Page 80: ...available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY SEATING 32 632837G04 Seat Bottom Assembly Includes Item...

Page 81: ...Page L 4 696883 Service Parts Manual Notes SEATING...

Page 82: ...Manual SEATING 31 1 42 43 2 8 9 10 11 16 41 20 19 19 19 21 19 35 36 36 36 37 35 17 25 26 28 28 28 28 29 29 27 18 32 33 11 12 3 4 3 Rear Flip Seat Handrail Kit includes items 32 37 Flip Seat Bottom As...

Page 83: ...3 8 16 1 5 6 7 8 634179 Footrest Weldment 1 9 19853G1 Square Tube Cap 1 1 10 00427G6 Hex Head Bolt 3 8 16 x 1 25 Lg Grade 5 1 11 614221 Flat Washer 3 8 2 12 11098G5 Lock Nut 3 8 16 1 13 14 15 16 6341...

Page 84: ...art Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY SEATING 32 634185 Footrest Handle Weldment 1 33 19859G1 Square Tube Cap 3 4 2 34 35...

Page 85: ...Page L 8 696883 Service Parts Manual Notes SEATING...

Page 86: ...L C FRONT Outside Tubing On Sun Top Front of Vehicle Front of Vehicle DETAIL B 4 5 27 25 26 28 29 22 17 15 15 Driver Side Shown D B A C DETAIL D REAR Passenger Side Shown Front of Vehicle 2 11 7 6 3 8...

Page 87: ...river Side 1 5 602741 Rear Strut Passenger Side 1 6 19853G1 End Cap 1 Sq 1 7 24647G1 Spacer 1 4 1 8 00891G5 Lock Nut 3 8 16 2 9 10 00665G6 Hex Head Bolt SS 3 8 16 x 2 Lg 1 11 00665G3 Hex Head Bolt SS...

Page 88: ...Page N 3 696883 Service Parts Manual Notes WEATHER PROTECTION...

Page 89: ...Page N 4 696883 Service Parts Manual Notes WEATHER PROTECTION...

Page 90: ...e N 5 696883 Service Parts Manual WEATHER PROTECTION Strut Rubber Latch Front of Vehicle Windshield Retainer 6 5 3 7 4 Split Windshield Kit Clear includes items 2 8 1 Hardware Kit includes items 3 7 2...

Page 91: ...Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page N 6 696883 Service Parts Manual WEATHER PROTECTION 1 71966G05 Split Windshield Kit Clear Includes Ite...

Page 92: ...Page N 7 696883 Service Parts Manual Notes WEATHER PROTECTION...

Page 93: ...Page N 8 696883 Service Parts Manual Notes WEATHER PROTECTION...

Page 94: ...Page N 1 696883 Service Parts Manual WHEELS AND TIRES Wheel and Tire design may vary by Part Number 3 2 1...

Page 95: ...is not available as an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page N 2 696883 Service Parts Manual WHEELS AND...

Page 96: ...Page N 3 696883 Service Parts Manual Notes WHEELS AND TIRES...

Page 97: ...Page N 4 696883 Service Parts Manual Notes WHEELS AND TIRES...

Page 98: ...ldren unattended or allow children to play on the vehicle Never leave key in parked vehicle Never carry more than 2 occupants on each bench seat Never exceed vehicle weight capacity see owner s guide...

Page 99: ...r Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page P 2 696883 Service Parts Manual DECALS AND LABELS 1 698039 Cowl Decal 1 2 685698 MADE IN USA Decal 1 3 69528...

Page 100: ...Page P 3 696883 Service Parts Manual Notes DECALS AND LABELS...

Page 101: ...Page P 4 696883 Service Parts Manual Notes DECALS AND LABELS...

Page 102: ...n Road Augusta Georgia USA 30906 3852 Dealer 800 296 4804 Consumer 877 394 6727 Owner s Guides and Repair Manuals are available from the manufacturer Copyrighted Material This manual may not be reprod...