Ignition Switch; Ignition Coil - Tracker Off-Road 500S Service Manual

NOTE: The maintainer/charger will charge the bat-

tery to 95% capacity at which time the Maintenance
Charge Indicator (D) will illuminate and the main-
tainer/charger will change to pulse/float maintenance.
If the battery falls below 12.9 DC volts, the charger
will automatically start again at the first step of the
charge sequence.
3300C
NOTE: Not using a battery charger with the proper

float maintenance will damage the battery if con-
nected over extended periods.
Charging
 NOTE: The manufacturer recommends the use of
the CTEK Multi US 800 or the CTEK Multi US 3300
for battery maintenance charging.
1. Be sure the battery and terminals have been cleaned
with a baking soda and water solution.
2. Be sure the charger and battery are in a well-venti-
lated area and ensure the battery charger cables will
not contact any battery acid. Be sure the charger is
unplugged from the 110-volt electrical outlet.
3. Connect the red terminal lead from the charger to the
positive terminal of the battery; then connect the
black terminal lead of the charger to the negative ter-
minal of the battery.
4. Plug the charger into a 110-volt electrical outlet.
5. By pushing the Mode button (A) on the left side of
the charger, select the Normal Charge Icon (E). The
Normal Charge Indicator (C) should illuminate on
the upper left portion of the charger.
6. The battery will charge to 95% of its capacity at
which time the Maintenance Charge Indicator (D)
will illuminate.
NOTE: For optimal charge and performance, leave

the charger connected to the battery for a minimum 1
hour after the Maintenance Charge Indicator (D) illu-
minates. If the battery becomes hot to the touch, stop
charging. Resume after it has cooled.
7. Once the battery has reached full charge, unplug the
charger from the 110-volt electrical outlet.
 NOTE: If, after charging, the battery does not perform
to operator expectations, bring the battery to an autho-
rized dealer for further troubleshooting.
100

Ignition Switch

The ignition switch connector can be accessed by remov-
ing the front left splash panel.
VOLTAGE
NOTE: Perform this test on the harness connector.

1. Set the meter selector to the DC Voltage position.
2. Connect the red meter lead to the red wire; then con-
nect the black meter lead to battery ground.
3. Meter must show battery voltage.
NOTE: If the meter shows no battery voltage, trou-

bleshoot the main 30-amp fuse (PDM), the battery, or
the main wiring harness.
4. With the switch connected to the harness, connect
the red meter lead to the red/black wire and the black
meter lead to ground; then turn the ignition switch to
the ON position. The meter must show battery volt-
age.
5. Connect the red meter lead to the yellow/green wire;
then with the black meter lead grounded, turn the
ignition switch to the START position. The starter
should engage and the meter must show battery volt-
age.
 NOTE: When the starter is engaged, battery voltage
will be approximately 10.8 DC volts.

Ignition Coil

The ignition coil is mounted under the seat below the
passenger's side.
VOLTAGE
Primary Coil
1. Set the meter selector to the DC Voltage position;
then disconnect the primary connector from the igni-
tion coil.
2. Connect the red tester lead to the orange wire and the
black tester lead to ground.
3. Turn the ignition switch to the ON position. The
meter must show battery voltage.
Secondary Coil
CAUTION
Disconnect the injector connector before performing
the following procedure.
1. Connect the primary ignition coil connector. Remove
the spark plug cap from the spark plug.
2. Connect the spark plug cap to Ignition Test Plug or
other suitable tool; then ground the tool away from
the spark plug hole. While turning the engine over,
check for sufficient spark.