Tracker Off-Road LX6 Li, Service & Parts Manual

Page 1: ...SERVICE PARTS MANUAL 696886 B Revised 07 19 Issued 05 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 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 Acceler...

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: ...r of 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 ACCEL...

Page 13: ...Page A 4 696886 Service Parts Manual Notes ACCELERATOR...

Page 14: ...Page B 1 696886 Service Parts Manual BATTERY CHARGER 1 3...

Page 15: ...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 6968...

Page 16: ...Page B 3 696886 Service Parts Manual Notes BATTERY CHARGER...

Page 17: ...Page B 4 696886 Service Parts Manual Notes BATTERY CHARGER...

Page 18: ...Page C 1 696886 Service Parts Manual BODY 5 4 3 2 7 6 1 19 20 12 14 15 21 17 18 13 16 10 9 8 Front of Vehicle Front of Vehicle...

Page 19: ...Grade 5 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 Alumin...

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 696886 Service Parts Manual BODY 63 86 89 15 14 19 23 24 17 18 22 13 11 12 9 20 21 Front of Vehicle 2 10 72 1 2 3 4 5...

Page 23: ...lt 5 16 18 x 3 4 Lg Grade 5 2 4 00559G8 Flat Washer 5 16 2 5 11098G6 Lock Nut 5 16 18 2 6 7 8 9 10570G10 Domed Rivet SS 5 32 x 9 16 Lg 10 10 14601G11 Rivet Aluminum 3 16 x 9 16 Lg 5 11 70451G01 Lower...

Page 24: ...Page C 7 696886 Service Parts Manual BODY 1 2 6 7 7 8 10 9 3 Front of Vehicle 19 18 Rear Bumper Installation 16 14 15 14 17 12 Front of Vehicle 21 22 4 27 26 23 Front of Vehicle 24...

Page 25: ...56 Lg 2 4 633917 Rivet Plastic 2 5 6 71320G01 Access Panel 1 7 01107G01 Pan Head Torx Screw SS 8 x 63 Lg 5 8 16816G2 Ratchet Rivet 25 x 887 2 9 71609G01 Seat Hinge Plate 2 10 10570G11 Rivet SS 5 32 x...

Page 26: ...Page C 9 696886 Service Parts Manual Notes BODY...

Page 27: ...Page C 10 696886 Service Parts Manual Notes BODY...

Page 28: ...696886 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 29: ...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 30: ...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 31: ...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 32: ...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 33: ...Page D 6 Notes BRAKES 696886 Service Parts Manual...

Page 34: ...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 35: ...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 Passen...

Page 36: ...Page D 9 Notes BRAKES 696886 Service Parts Manual...

Page 37: ...Page D 10 Notes BRAKES 696886 Service Parts Manual...

Page 38: ...Page E 1 696886 Service Parts Manual ELECTRICAL Note FRAME SHOWN PARTIALLY 1...

Page 39: ...of 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 Page E...

Page 40: ...Page E 3 696886 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 41: ...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 42: ...Page E 5 696886 Service Parts Manual ELECTRICAL 6 3 10 7 9 1 2 11 4 8 10 Front of Vehicle Battery Pack ADVANCED BATTERY 2 MODULE 13 14...

Page 43: ...Page E 6 696886 Service 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...

Page 44: ...Page E 7 696886 Service Parts Manual ELECTRICAL 5 ADVANCED BATTERY 3 MODULE Front of Vehicle 4 3 1 2 NOTE Refer to ADVANCED BATTERY 2 MODULE for exploded view of battery pack...

Page 45: ...an individual part Indicates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page E 8 696886 Service Parts Manual ELECTRICAL 1 651961 Battery Comm...

Page 46: ...Page E 9 696886 Service Parts 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 13 14 3...

Page 47: ...5 DESCRIPTION QTY Page E 10 696886 Service Parts Manual ELECTRICAL 1 651531 Charger Receptacle 51V 1 2 71055G02 Rivet 3 16 Dia 4 3 32860G1 Horn 1 4 656108 DC DC Converter Assembly Includes Items 5 7 1...

Page 48: ...Page E 11 696886 Service Parts Manual ELECTRICAL 17 25 13 15 21 12 Control Panel Assembly includes items 13 17 23 22 16 Solenoid Installation 5 1 4 3 2 Front of Vehicle To Battery Positive 14...

Page 49: ...oid 1 2 16469G1 Fender Washer 2 3 00414G6 Hex Head Bolt 1 4 20 x 25 Lg Grade 5 2 4 11027G2 Flanged Lock Nut 1 4 20 2 5 12914G1 Faston Tab 2 6 7 8 9 10 11 12 697126 Control Panel Assembly Includes Item...

Page 50: ...icle LED Headlight Assembly Passenger Side includes item 3 2 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...

Page 51: ...1411G03 LED Headlight 1 4 5 6 71597G01 Self Threading Nut 5mm x 10mm x 15mm 4 7 71781G02 Vinyl Tape 1 8 9 10 677730 Jumper Harness Hi Low Led Headlight 1 11 12 664780 Jumper Harness Turn Signal Lights...

Page 52: ...Page E 15 696886 Service Parts Manual Notes ELECTRICAL...

Page 53: ...Page E 16 696886 Service Parts Manual Notes ELECTRICAL...

Page 54: ...Page F 1 696886 Service Parts Manual ELECTRONIC SPEED CONTROL Front of Vehicle Part of Frame 2 3 8 8 5 11 9 10 5 4 7 6 1 Controller Assembly includes items 2 8 Main Motor Wires 12...

Page 55: ...ual ELECTRONIC SPEED CONTROL 1 696692 Controller Assembly Includes Items 2 8 1 2 696571 Controller Bracket 1 3 697454 Controller 1234SE 1 4 606264 Flanged Hex Head Bolt M6 1 x 20mm Lg Grade 8 8 2 5 45...

Page 56: ...Page F 3 696886 Service Parts Manual Notes ELECTRONIC SPEED CONTROL...

Page 57: ...Page F 4 696886 Service Parts Manual Notes ELECTRONIC SPEED CONTROL...

Page 58: ...NG Spindle and Hub Assembly 4 Lug Passenger Side includes items 4 13 Spindle and Hub Assembly Driver Side includes items 5 13 17 3 16 Front of Vehicle 27 27 29 26 26 28 30 Part of Frame Steering Box A...

Page 59: ...632926 Bearing O D 28mm 1 7 25146G1 Grease Seal 1 8 11750G2 Roller Bearing and Race Assembly 2 9 35886G01 Wheel Hub 1 10 11 12093G1 Slotted Nut 1 14 1 12 00798G8 Cotter Pin 5 32 x 1 3 4 Lg 1 13 12091G...

Page 60: ...G 3 696886 Service Parts Manual FRONT SUSPENSION AND STEERING Steering Box Assembly includes items 2 23 1 Rack Ball Joint includes items 24 25 23 9 8 7 6 12 13 14 15 16 21 10 18 20 4 17 24 25 26 19 11...

Page 61: ...50G01 Retaining Ring External 1 6 15112G1 Ball Bearing O D 1 65 x I D 78 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...

Page 62: ...SPENSION AND STEERING Steering Column Kit includes items 13 25 Tie Rod Assembly includes items 37 41 10 32 1 2 5 32 37 3 16 18 17 24 30 31 22 21 20 7 41 40 38 39 14 13 6 15 12 36 8 4 25 9 Axle Shown F...

Page 63: ...60G2 Flat Washer 7 16 7 7 00734G1 Lock Nut 7 16 14 3 8 00532G7 Hex Nut 1 4 20 1 9 01006G01 Hex Washer Head Bolt 3 8 16 x 1 1 4 Lg 4 10 00879G1 Lock Washer 3 8 4 11 12 70758G05 Steering Column Assembly...

Page 64: ...stomer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY FRONT SUSPENSION AND STEERING 32 00734G1 Lock Nut 7 16 14 2 33 34 35 36 70876G02 Tie Rod Assembly 26 44 Lg I...

Page 65: ...Page G 8 696886 Service Parts Manual Notes FRONT SUSPENSION AND STEERING...

Page 66: ...Page H 1 696886 Service Parts Manual MOTOR 7 10 2 11 12 Front of Vehicle Part of Motor 1 Rear Axle 6 14 5 6 5 Front of Vehicle 17 18 19 20...

Page 67: ...ge H 2 696886 Service Parts Manual MOTOR 1 681071 Motor 72V 1 2 601327 Lock Washer 6mm 6 3 4 5 00915G1 Bonded Seal Washer 1 4 I D 3 6 616716 Hex Head Bolt M6 1 x 16mm Lg 3 7 605741 Hex Head Bolt M6 1...

Page 68: ...Page H 3 696886 Service Parts Manual Notes MOTOR...

Page 69: ...Page H 4 696886 Service Parts Manual Notes MOTOR...

Page 70: ...1 696886 Service Parts Manual REAR AXLE 24 12 13 10 23 11 17 21 29 20 7 31 8 30 22 19 36 18 36 9 33 2 25 9 14 7 29 32 19 36 18 36 36 35 34 28 35 36 17 Front of Vehicle 1 Rear Axle 16 99 1 includes ite...

Page 71: ...4 5 6 7 15118G1 Hex Head Bolt 3 8 16 X 2 125 Lg 4 8 15558G1 Hex Head 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 23530G...

Page 72: ...lt Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY REAR AXLE 32 620349 Intermediate Gear Assembly 1 33 620350 Drive Gear 1 34 620355 Ball Bearing 1 35 620...

Page 73: ...Page J 4 696886 Service Parts Manual Notes REAR AXLE...

Page 74: ...696886 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 19 20 8 7 11 9 3 2 4 5 2 3 26 27 21 24 25 6 Front of Vehicle...

Page 75: ...2 5 10044G01 Vinyl Cap 1 6 667990 Leaf Spring 2 7 624030 Flanged Bushing 2 8 652708G03 Lift Bracket 1 9 00560G1 Flat Washer 3 8 8 10 11098G5 Lock Nut 3 8 16 4 11 00430G12 Hex Head Bolt 3 8 16 x 5 1 2...

Page 76: ...Page K 3 Notes REAR SUSPENSION 696886 Service Parts Manual...

Page 77: ...Page K 4 Notes REAR SUSPENSION 696886 Service Parts Manual...

Page 78: ...Manual Page L 1 SEATING 15 14 19 16 17 18 13 20 23 21 22 Seat Bottom Assembly includes items 14 23 Front of Vehicle 25 27 26 Front of Vehicle 4 7 3 6 8 1 2 10 11 Seat Support Weldment Seat Back Assemb...

Page 79: ...SS 8 15 x 1 Lg 4 7 645021 Seat Back Base 1 8 01107G01 Torx Screw 8 x 5 8 Lg 4 9 10 00661G8 Hex Head Bolt 1 4 20 x 1 2 Lg 4 11 00664G7 Lock Washer 255 x 263 4 12 13 629269G0104 Seat Bottom Assembly Gra...

Page 80: ...8 21 26 28 26 30 37 28 26 26 22 Top of Vehicle Front of Vehicle 3 5 5 6 10 2 28 Flip Flop Seat Bottom includes items 11 15 15 Seat Bottom Assembly includes items 16 18 1 Handrail Kit Flip flop Seat in...

Page 81: ...lip Flop Seat Bottom Gray Includes Items 11 15 1 11 634190 Deck Board Assembly 1 12 16705G1 Truss Head Phillips Screw SS 1 4 20 x 1 Lg 5 13 617402 Seat Strap 1 14 00559G7 Flat Washer 1 4 1 15 632837G0...

Page 82: ...ates consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY SEATING 696886 Service Parts Manual 32 01006G01 Hex Head Bolt 3 8 16 x 1 25 Lg 2 33 71204G01...

Page 83: ...Page L 6 Notes SEATING 696886 Service Parts Manual...

Page 84: ...696886 Service Parts Manual Page L 7 SEATING 14 21 1 30 30 23 4 18 18 3 21 22 5 29 28 27 26 18 30 12 12 9 8 15 16 17 Floor Panel Front of Vehicle 24 25...

Page 85: ...10570G11 Rivet SS 3 16 x 70 Lg 4 10 11 12 71055G01 Rivet Aluminum 3 16 x 1 Lg 3 13 14 00439G8 Hex Head Bolt SS 5 16 18 x 2 Lg Grade 5 2 15 00675G1 Flat Washer SS 398 I D x 1 25 O D x 115 Lg 2 16 7188...

Page 86: ...1 5 6 8 9 7 10 11 27 2 Seat Back Support Seat Pod 3 Seat Back Assembly includes item 5 7 10 4 Seat Back Assembly includes items 6 9 11 12 Seat Bottom Assembly includes items 15 18 26 13 Seat Bottom A...

Page 87: ...Seat Back Cover 1 8 71754G01 Seat Back Padding 1 9 645021 Seat Back Base 1 10 648271 Pan Head Torx Screw SS 8 15 x 1 Lg 4 11 01107G01 Pan Head Torx Screw SS 8 x 63 Lg 4 12 629269G1704 Seat Bottom Ass...

Page 88: ...Page L 11 Notes SEATING 696886 Service Parts Manual...

Page 89: ...Page L 12 Notes SEATING 696886 Service Parts Manual...

Page 90: ...ck includes items 2 6 Driver Side Shown Front of Vehicle B 1 7 8 8 21 18 20 19 9 10 11 4 5 6 Sun Top Hardware Kit includes items 7 21 23 Windshield Kit includes item 24 Front of Vehicle Front of Vehic...

Page 91: ...2 Rear Support Passenger Side 1 6 608138 Sun Top Hardware Kit Includes Items 7 21 1 7 00665G5 Hex Head Bolt SS 3 8 16 x 1 Lg 4 8 00679G1 Flat Washer SS 3 8 8 9 00771G5 Nylon Washer 3 8 4 10 00891G5 Lo...

Page 92: ...Page M 3 696886 Service Parts Manual Notes WEATHER PROTECTION...

Page 93: ...Page M 4 696886 Service Parts Manual Notes WEATHER PROTECTION...

Page 94: ...Page N 1 696886 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 696886 Service Parts Manual WHEELS AND...

Page 96: ...Page N 3 696886 Service Parts Manual Notes WHEELS AND TIRES...

Page 97: ...Page N 4 696886 Service Parts Manual Notes WHEELS AND TIRES...

Page 98: ...ldren 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 Never alter vehicle to increa...

Page 99: ...consult Customer Service Department for additional information ITEM PART NO 1 2 3 4 5 DESCRIPTION QTY Page P 2 DECALS AND LABELS 696886 Service Parts Manual 1 698039 Cowl Decal 1 2 685698 MADE IN USA...

Page 100: ...Page P 3 Notes DECALS AND LABELS 696886 Service Parts Manual...

Page 101: ...Page P 4 Notes DECALS AND LABELS 696886 Service Parts Manual...

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...