Starter Motor; Starter Relay - Tracker Off-Road 500S Service Manual

3. Slowly increase RPM. The voltage should increase
with the engine RPM. The charging voltage should
be greater than resting battery voltage (key off). The
charging voltage should not exceed a maximum of
15.0 DC volts.
CAUTION
Do not run the engine at high RPM for more than 10 seconds.
 NOTE: If voltage rises above 15.0 DC volts, the reg-
ulator is faulty or a battery connection is loose or cor-
roded. Clean and tighten battery connections or
replace the regulator/rectifier. If voltage does not rise,
replace the regulator/rectifier.

Starter Motor

 NOTE: The starter motor is only serviceable as an
assembly.
REMOVING
1. Disconnect the battery.
CAUTION
Always disconnect the negative battery cable from the
battery first; then disconnect the positive cable.
2. Remove the nut securing the positive cable to the
starter; then remove the cable from the starter.
3. Remove the two cap screws securing the starter with
ground wires to the crankcase; then remove the
starter. Account for the wiring forms and an O-ring.
INSTALLING
1. Apply a small amount of grease to the O-ring seal on
the starter; then install the starter into the crankcase.
Secure with two machine screws and wiring forms.
2. Secure the positive cable to the starter with the nut.
3. Connect the battery. Positive cable first, then nega-
tive.
TESTING VOLTAGE
Perform this test on the starter positive terminal. To
access the terminal, slide the boot away.
NOTE: The ignition switch must be in the ON posi-

tion, and the shift lever in the NEUTRAL position.
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the starter terminal;
then connect the black tester lead to ground.
3. With the starter switch engaged, the meter must
show battery voltage and the starter should operate.
NOTE: The meter will read slightly low due to the

normal electrical draw of the starter motor.
PK303
NOTE: If the meter showed correct voltage but the

starter motor did not operate or operated slowly,
troubleshoot all starting system components before
replacing the starter motor.
NOTE: If the meter showed no battery voltage,

inspect the battery voltage (at the battery), 30-amp
main fuse in the PDM, starter switch, starter relay, or
main wiring harness.

Starter Relay

1. Remove the seat and battery box cover; then, using
the multimeter set to the DC Voltage position, check
the relay as follows.
2. Connect the red tester lead to the positive battery ter-
minal; then connect the black tester lead to the starter
cable connection on the starter relay. The meter must
show battery voltage.
PK304A
NOTE: Make sure the ignition switch is in the ON

position and the transmission in neutral.
3. Depress the starter button while observing the multi-
meter. The multimeter should drop to near 0 volts
and a "click" should be heard from the relay.
NOTE: If a "click" is heard and more than one volt

is indicated by the multimeter, replace the starter
relay. If no "click" is heard and the multimeter con-
tinues to indicate battery voltage, proceed to step 4.
4. Disconnect the two-wire connector from the starter
relay; then connect the red tester lead to the yellow/
green wire and the black tester lead to the green wire.
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