ELECTRICAL COMPONENTS: 850 GASOLINE VEHICLE
Solenoid
Page 14-14
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
14
SOLENOID
See General Warning on page 1-1.
Testing the Solenoid
See Test Procedure 6 – Solenoid on page 12-15.
Solenoid Removal
1. Disconnect battery cables as instructed.
See WARNING “To avoid unintentionally starting...” in Gen-
eral Warning on page 1-2.
2. Remove electrical component box cover
(Figure 14-17, Page 14-15)
.
3. Disconnect all the wires from the solenoid.
4. Remove the two screws securing the solenoid in place. Remove the solenoid.
Solenoid Installation
1. Install the solenoid in the electrical component box. Use two screws to secure the solenoid to the box and
tighten to 14 in-lb (1.6 N·m).
2. Connect all wires as indicated.
See Wiring Diagram on page 12-6.
2.1. Connect the 6-gauge white wire from the starter/generator, the 18-gauge white wire from the fuel
gauge/hour meter, and the 16-gauge red wire from the voltage regulator to the large post on the
solenoid.
2.2. Connect the 6-gauge red wire from the battery terminal and the 10-gauge red wire from the fuse
block to the other large post on the solenoid.
2.3. Connect the 18-gauge orange wire from accelerator pedal limit switch to small post on the solenoid.
2.4. Connect the 18-gauge blue wire from the key switch to the other small post on the solenoid.
3. Tighten the hex nuts on the large solenoid posts to 60 in-lb (6.8 N·m). Tighten the nuts on the small sole-
noid posts to 22 in-lb (2.5 N·m).
4. Install the snap-on electrical box cover by pressing down firmly on all corners and install the screw, tight-
ening to 18 in-lb (2 N·m).
5. Connect battery cables, positive (+) cable first, and tighten hardware to 144 in-lb (16 N·m)
(Figure 1-1,
Page 1-3)
. Coat terminals with Battery Terminal Protector Spray (CCI P/N 1014305) to minimize corro-
sion.
FUSE
See General Warning on page 1-1.
Testing the Fuse
See Test Procedure 2 – Fuse on page 12-12.
Fuse Removal
1. Disconnect battery cables as instructed.
See WARNING “To avoid unintentionally starting...” in Gen-
eral Warning on page 1-2.
2. Remove electrical component box cover.
3. Remove the fuse from the fuse block.
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