ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE
Troubleshooting
Page 21-8
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
21
TROUBLESHOOTING GUIDE 2
TROUBLESHOOTING GUIDE 2
SYMPTOM
POSSIBLE CAUSES
CORRECTIVE ACTION
Vehicle does not operate
Batteries discharged
Charge batteries
Improper or poor battery connections
Check vehicle wiring.
See Wiring
Diagram on page 21-2.
Battery charger is connected to the
vehicle – Solenoid lockout feature has
disabled the vehicle
Disconnect the battery charger from the
vehicle
Onboard computer failure
Test Procedure 2 – Onboard Computer
Solenoid Lockout Circuit on page 21-11
Key switch and MCOR limit switch circuit
Check for loose or disconnected wires at
key switch and MCOR
Failed key switch
Test Procedure 8 – Key Switch and
MCOR Limit Switch Circuit on page 21-16
Failed MCOR
Test Procedure 8 – Key Switch and
MCOR Limit Switch Circuit on page 21-16.
See also Test Procedure 4 – MCOR
Voltage on page 21-12.
Forward/Reverse rocker switch
Test Procedure 15 – Forward/Reverse
Rocker Switch on page 21-30
Solenoid – loose wires
Test Procedure 3 – Solenoid Activating
Coil on page 21-12
Solenoid – failed coil
Test Procedure 3 – Solenoid Activating
Coil on page 21-12
Solenoid – failed solenoid diode
Test Procedure 3 – Solenoid Activating
Coil on page 21-12
Speed controller thermal cutback
Allow controller to cool and ensure that
vehicle is not over-loaded before returning
to operation
16-pin connector at speed controller
Check for loose or disconnected wires at
the 16-pin connector.
See also Test
Procedure 9 – 16-Pin Connector on
page 21-18.
High pedal detect
Cycle accelerator pedal
Motor stall
Cycle accelerator pedal
Motor failure
Section 26 – Motor (Model
5BC59JBS6390) or Section 27 – Motor
(Model EJ4-4001)
Failed Tow/Run switch
Test Procedure 6 – Tow/Run Switch on
page 21-15
Speed controller failure
Replace speed controller.
See Speed
Controller Removal, Section 23,
Page 23-13.
Troubleshooting Guide continued on next page...
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