90
4. With the ignition switch in the ON position, select
the DC volts position on the tester; then apply either
brake. The meter must read battery voltage. If battery
voltage is observed and no audible “click” was heard
in step 1 or 2, remove the tester leads and replace the
start-in-gear relay.
5. Shift the gear selector out of neutral and connect a
jumper wire between the yellow/green wire (2) and
the green wire (4).
KM460A
6. Momentarily depress the starter button. The starter
should engage. If the starter engages, replace the
start-in-gear relay. If the starter does not engage,
troubleshoot the battery connections, starter relay, or
starter connections.
Headlights
On the Utility, the connectors are the two 3-prong ones
secured to the front bumper supports (one on each side)
with cable ties.
On the DVX, the connectors are the two 3-prong ones
under the front fender.
BULB VERIFICATION (LO and HI
Beam)
Visually inspect the bulb for broken filaments, blacken-
ing, or loose bulb base.
VOLTAGE
NOTE: Perform this test in turn on the main harness
side of the connectors. Also, the ignition switch must be
in the LIGHTS position and the engine must be running.
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the green wire; then
connect the black tester lead to the white wire.
3. With the dimmer switch in the LO position (LO
beam), the meter must show battery voltage.
4. Connect the red tester lead to the blue wire. With the
dimmer switch in the HI position (HI beam), the
meter must show battery voltage.
NOTE: If battery voltage is not shown in any test,
inspect the fuses, battery, main wiring harness, con-
nectors, or the left handlebar switch.
Taillight - Brakelight
The connector is the 3-prong one located under the rear
fender assembly.
BULB VERIFICATION
Visually inspect the bulb for broken filaments, blacken-
ing, or loose bulb base.
VOLTAGE (Taillight)
NOTE: Perform this test on the main harness side of
the connector. Also, the ignition switch should be in
the LIGHTS position.
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the brown/black wire;
then connect the black tester lead to the green wire.
3. With the ignition key in the LIGHTS position, the
meter must show battery voltage.
NOTE: If the meter shows no voltage, inspect fuses,
wiring harness, connectors, and switches.
VOLTAGE (Brakelight)
NOTE: Perform this test on the main harness side of
the connector. Also, the ignition switch should be in
the ON position and the brake (either foot pedal or
hand lever) must be applied.
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the green/yellow wire;
then connect the black tester lead to the green wire.
3. With either brake applied, the meter must show bat-
tery voltage.
NOTE: If the meter shows no voltage, inspect fuses,
wiring harness, connectors, and switches.
Ignition Timing
The ignition timing cannot be adjusted; however, verify-
ing ignition timing can aid in troubleshooting other com-
ponents. To verify ignition timing, use the following
procedure.
1. Attach the Timing Light to the spark plug high ten-
sion lead; then remove the timing inspection plug
from the left-side crankcase cover.
2. Using the Tachometer, start the engine and run at
1000 RPM; ignition timing should be 5° BTDC (“F”
mark).
3. Install the timing inspection plug.
If ignition timing cannot be verified, the rotor may be
damaged, the key may be sheared, the trigger coil bracket
may be bent or damaged, or the CDI unit may be faulty.
