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ELECTRICAL COMPONENTS: 800 AND 810 GASOLINE VEHICLES
Light Switch
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Page 13-29
13
Voltage Limiter Installation
1. Mount the voltage limiter to the frame using the mounting hardware and tighten to 25 in-lb (2.8 N·m)
(Figure 13-29, Page 13-28)
.
2. Connect the black/white wire from harness to the negative (–) terminal on the diode.
3. Connect the solid black wire from the ground terminal block to the positive (+) terminal on the diode.
4. Install the instrument panel in reverse order of removal.
See Key Switch Removal on page 13-14.
5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16.3 N·m). Coat
terminals with Battery Terminal Protector Spray (CCI P/N 1014305).
LIGHT SWITCH
See General Warning on page 1-1.
Testing the Light Switch
See Test Procedure 28, Section 11, Page 11-36.
Light Switch Removal
1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in the NEUTRAL posi-
tion. Chock the wheels.
2. Disconnect the battery cables as instructed.
See WARNING “To avoid unintentionally starting...” in
General Warning on page 1-2.
3. Loosen the set screw locking the light switch knob (1) to the shaft
(Figure 13-30, Page 13-28)
.
4. Remove the instrument panel.
See Key Switch Removal on page 13-14.
5. Disconnect the wires from the light switch.
6. Remove the outer nut (2) from the light switch (3) and remove.
Light Switch installation
1. Connect the wires to the light switch.
See Wiring Diagrams, Section 11, Page 11-6.
2. Thread the check nut (4) onto the switch until an equal number of threads show on both sides. Install to
the instrument panel with nut (2) on the outside of the dash and tighten the nut to 14 in-lb (1.6 N·m)
(Figure 13-30, Page 13-28)
.
3. Push the light switch shaft in. Screw the knob onto the end of the shaft until the knob touches the outer
nut. Then turn the knob in the opposite direction until the headlight beams on the knob are horizontal to
the ground. Tighten the set screw to lock the knob to the shaft.
4. Install the instrument panel in reverse order of removal.
See Key Switch Removal on page 13-14.
5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 144 in-lb (16.3 N·m). Coat
terminals with Battery Terminal Protector Spray (CCI P/N 1014305).
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