Tracker Off-Road 800SX Service Manual page 123

MOD295B
MOD566
4. Mark the fuel pump mounting and gas tank for
installing purposes; then using a suitable tool,
remove the fuel tank nut securing the fuel pump to
the gas tank and remove the fuel pump.
CAUTION
Take care not to damage the float or float arm or
replacement of the entire assembly will be necessary.
5. Using duct tape or other suitable means, cover the
fuel pump opening.
Inspecting
AT THIS POINT
If the pump has failed earlier test and must be replaced,
proceed to INSTALLING.
1. Inspect the fuel screen and blow clean with low pres-
sure compressed air.
2. Move the float lever and check for free movement.
The float assembly should return to the lower posi-
tion without force.
3. Test the fuel level sensor by connecting a multimeter (A)
to the fuel level sensor leads (B); then select OHMS. The
multimeter should show 5 ohms at full fuel position (C)
and 95 ohms at empty fuel position (D).
ATV2116
NOTE: If readings are erratic, clean the resistor

wiper and resistor with clean alcohol and retest. If
still not correct, replace the fuel pump assembly.
Replacing Fuel Level Sensor
To replace the fuel level sensor, use the following proce-
dure:
1. Cut the two blue wires (A) in the location shown.
2. Slide the existing sensor assembly (B) up and off the
fuel pump assembly housing.
XR257A
3. Keeping the float attached to the float arm, remove
the float arm from the existing fuel level sensor.
Press the float arm into the new fuel level sensor
assembly. Ensure it locks into place.
XM366
NOTE: Inspect the float for any damage or leaking

by submerging in water and looking for any air bub-
bles. Replace if damaged.
4. Install the fuel level sensor assembly onto the fuel
pump assembly housing. Once inserted, press down
to make sure it locks into place.
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