Tracker Off-Road 800SX Service Manual page 122

2. Remove the sensor from the sensor housing account-
ing for an O-ring.
3. Install the new speed sensor into the housing with a
new O-ring lightly coated with multi-purpose grease;
then secure the sensor with the cap screw (threads
coated with blue Loctite #242). Tighten securely.
MOD488A
FUEL PUMP/FUEL LEVEL SENSOR
Component data can be retrieved using the Dealer Diag-
nostic Service. Utilize the Sensor Data screen.
NOTE: The fuel pump and fuel level sensor are only

serviceable as assemblies.
Testing
! 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.
AT THIS POINT
Prior to removing the electric fuel pump, the following
check should be performed to determine that removal is
necessary.
1. Turn the ignition switch ON and listen for a momen-
tary "whirring" sound of the pump building pressure.
If the sound is heard (several seconds), no electrical
checks are necessary. Turn the ignition switch OFF.
! WARNING
Fuel may be under pressure. De-pressurize the fuel sys-
tem by disconnecting the fuel pump electrical connec-
tor (A) and running the engine until it stalls. Place an
absorbent towel around the connector to absorb any
fuel when disconnecting.
120
MOD295B
2. Disconnect the fuel hose (B) from the fuel pump;
then install the EFI Fuel Pressure Test kit.
MOD566
3. Reconnect the fuel pump electrical connector (A);
then turn the ignition switch to the ON position. The
fuel pressure should build until the pump shuts off.
Pressure should read 3.0 kg-cm
4. If the pump is not running, disconnect the fuel pump/
sensor connector (A).
5. Connect a multimeter to the power supply leads with
the red tester lead to the orange/red wire and the
black tester lead to the black wire; then turn the igni-
tion switch to the ON position. The meter should
read battery voltage. If battery voltage is indicated
and the fuel pump does not run, replace the pump
assembly. If no battery voltage is indicated, check
the ECM, fuel relay, fuse, and the vehicle tilt sensor.
Removing Fuel Pump Assembly
1. Remove the key from the ignition switch.
! WARNING
Always ensure that power cannot be inadvertently
applied to the ignition/ECM when working on the fuel
system. If the ignition switch is turned on, the electric
fuel pump will start and gas could be rapidly pumped
and spilled resulting in fire and severe injury.
2. Tilt the cargo box up; then remove the driver-side
rear inner fender; then remove the CVT cover; then
disconnect the negative battery cable.
3. Disconnect the electrical plug (A) from the main har-
ness; then disconnect the fuel hose (B) from the fuel
pump.
(43.5 psi).
2