Fuel/Lubrication/Cooling; Throttle Body; Gas Tank - Tracker Off-Road 800SX Service Manual

Fuel/Lubrication/
Cooling
NOTE: Some photographs and illustrations used in

this section are used for clarity purposes only and are
not designed to depict actual conditions.
TROUBLESHOOTING
1. Verify that the electric fuel pump is operating by lis-
tening for a "whirring" sound for several seconds
after the key switch is turned to the ON position. If
no sound can be heard, see FUEL PUMP/FUEL
LEVEL SENSOR in Electrical System.
2. Check for a flashing Engine Management Malfunc-
tion icon on the LCD. If this is flashing, see Gauge
Diagnostic Menu in Electrical System.
3. Make sure there is sufficient, clean gas in the gas
tank.

Throttle Body

 NOTE: The throttle body is only serviceable as an
assembly (see the Electrical System section).

Gas Tank

! WARNING
Whenever any maintenance or inspection is made on
the fuel system during which there may be fuel leakage,
there should be no welding, smoking, open flames, etc.,
in the area.
REMOVING
NOTE: Gas tank removal should only be necessary

if the tank is leaking fuel or has been contaminated
with water or dirt, or inadvertently filled with diesel
fuel.
1. Remove the seats, seat backs, seat base, behind-the-
seat storage box panel, and side panels; then remove
the floor.
2. Disconnect the vent hose (A), fuel hose (B), and fuel
pump/gas level sensor connector (C); then cap the
vent fitting and gas hose fitting; then remove the fuel
tank.
MOD567
MOD566
MOD295A
CLEANING AND INSPECTING
 NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.
1. Clean the gas level sensor and gas pick-up screen.
2. Completely drain all contaminated gas from the gas
tank; then thoroughly wash the tank out with hot,
soapy water.
3. Dry the tank interior with compressed air.
NOTE: Repeat steps 2 and 3 until all contaminants

are removed.
4. Flush the fuel screen with hot, soapy water and dry
with compressed air.
NOTE: If any pinholes are noted in the gas screen,

replace the gas level sensor assembly.
5. Inspect the tank cap and filler neck for chipped or
broken threads.
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