Alternator/Regulator - Tracker Off-Road 800SX Service Manual

NOTE: If a "click" is heard and more than 1 volt is

indicated by the multimeter, replace the start relay. If
no "click" is heard and the multimeter continues to
indicate battery voltage, proceed to step 4.
4. Disconnect the start relay wire from the terminal on
the start relay; then connect the red tester lead to the
pink start relay wire (C) and the black tester lead to
the battery wire on the starter relay (D).
MOD569D
MOD572C
5. With the key switch momentarily held in the start
position, observe the multimeter.
NOTE: If battery voltage is indicated, replace the

starter relay.

Alternator/Regulator

TESTING
Prior to performing the following tests, make sure the
alternator belt is properly tightened and the battery is
fully charged.
1. Using a suitable multimeter, select the DC Voltage
position; then connect the red tester lead to the posi-
tive battery post and the black tester lead to the nega-
tive battery post.
2. Start the engine and slowly increase RPM. The volt-
age should increase with the engine RPM to a maxi-
mum of 15.5 DC volts.
126
NOTE: If voltage rises above 15.5 DC volts, the reg-

ulator is faulty or a battery connection is loose or cor-
roded. Clean and tighten battery connections or
replace the alternator. If voltage does not rise, check
all battery connections, the battery wire on the alter-
nator, and the voltage regulator wire. If all are nor-
mal, replace the alternator.
 NOTE: The alternator/regulator is only serviceable
as an assembly.
REMOVING
1. Remove the passenger rear inner fender; then
remove the negative battery cable from the battery.
2. Disconnect the battery wire from the alternator; then
disconnect the voltage regulator connector.
MOD573
3. Loosen the alternator adjuster cap screw (A) and the
pivot bolt (B); then remove the serpentine belt.
MOD439
4. Remove the adjuster cap screw and pivot bolt and
remove the alternator.
NOTE: The alternator/regulator is only serviceable

as an assembly.
INSTALLING
1. Place the alternator/regulator into position on the
engine; then secure with the existing hardware. Do
not tighten at this time.
2. Place the serpentine belt into position; then using a
suitable pry, tension the drive belt so that with a good
drive belt it does not spin on the pulley or make
noise.