Tracker Off-Road 500S Service Manual page 110

Replacing
To replace the fuel level sensor, use the following proce-
dure:
1. Cut the two blue wires (A) in the location shown.
XR257A
2. Slide the existing sender assembly (B) up and off the
fuel pump assembly housing.
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.
XR258
5. Connect the blue wires using the supplied splice con-
nectors from the fuel level sensor kit. Secure the
wires.
108
Installing
1. Place the fuel pump assembly into the gas tank with
a new gasket aligning the match marks; then secure
with the six screws. Tighten securely.
NOTE: It is important to install the fuel pump with

the correct orientation to ensure adequate float lever
clearance.
2. Connect the fuel hose connector to the fuel pump
pipe; then connect the electrical plug to the main har-
ness.
3. Connect the negative battery cable; then turn the
ignition switch to the ON position and verify that no
gas leaks are present, the pump runs for several sec-
onds, and the gas gauge reading is normal.
4. Start the engine to verify proper engine operation;
then shut off the engine and install the seat base, seat
back, and seat.
TILT SENSOR
! WARNING
Incorrect installation of the tilt sensor could cause sud-
den loss of engine power which could result in loss of
vehicle control resulting in injury or death.
CAUTION
Do not drop the tilt sensor as shock can damage the
internal mechanism.
Supply Voltage
1. Disconnect the three-wire connector from the sensor;
then select DC Voltage on the multimeter and con-
nect the red tester lead to the orange/blue wire (C)
and the black tester lead to the pink/black wire (A).
PK299A
2. Turn the ignition switch to the ON position. The
multimeter should read approximately 5 VDC. If
battery voltage is not indicated, check the connec-
tors, pins, or wiring harness.
3. Remove the red tester lead and connect to the blue/
brown wire. The multimeter should read less than
0.02 DC volts. If the specified voltage from steps 2
and 3 are not indicated, check wire connections at
the ECM or substitute another ECM to verify the
test.