Tracker Off-Road 800SX, Service Manual

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MOD482
5. Connect the blue wires using the supplied splice con-
nectors from the fuel level sensor kit. Secure the
wires.
Installing Fuel Pump Assembly
1. Place the fuel pump assembly into the fuel tank with
a new gasket aligning the match marks; then secure
with the fuel tank nut. Tighten to 70 ft-lb (95.2 N-m).

NOTE: It is important to install the fuel pump with
the correct orientation to ensure adequate float lever
clearance.
2. Connect the fuel hose and connect the return fuel
hose; then connect the electrical plug to the main
harness.
3. Connect the negative battery cable; then turn the
ignition switch to the ON position and verify that no
fuel leaks are present, the pump runs for several sec-
onds, and the fuel gauge reading is normal.
4. Start the engine to verify proper engine operation;
then shut off the engine and verify there are no leaks.
TILT SENSOR
Supply Voltage
1. Disconnect the three-wire connector from the sensor;
then select DC Voltage on the multimeter and con-
nect the red tester lead to the orange wire (C) and the
black tester lead to the pink/black wire (A).
MOD490
MOD491
2. Turn the ignition switch to the ON position. The
multimeter should read battery voltage. If battery
voltage is not indicated, check the 20-amp EFI relay
or the 10-amp EFI fuse in the PDM, wiring harness,
or the ignition switch.
3. Remove the red tester lead and connect to the blue/
brown wire. The multimeter should read less than 0.2
DC volts. If the specified voltage is not indicated,
check wire connections at the ECM or substitute
another ECM to verify the test.
Output Voltage

NOTE: Needle adapters will be required on the mul-
timeter leads as the following tests are made with the
sensor connected.
1. Connect the three-wire plug to the sensor; then
remove the right-side mounting screw securing the
sensor.
MOD492
2. Install the needle adapters to the multimeter leads;
then select DC Voltage on the multimeter.
! WARNING
Incorrect installation of the tilt sensor could cause sud-
den loss of engine power which could result in loss of
vehicle control resulting in injury or death.
CAUTION
Do not drop the tilt sensor as shock can damage the
internal mechanism.