ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE
Troubleshooting
Page 21-18
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
21
TEST PROCEDURE 9 – 16-PIN CONNECTOR
See General Warning on page 1-1.
1. Disconnect the battery cables as instructed.
See WARNING “To avoid unintentionally starting...” in
General Warning on page 1-1.
2. Disconnect the 16-pin connector from the speed controller. Inspect terminal ends inside plug to ensure
they are in position and seated in plug housing. If any terminals look like they are not pushed all the way
into the connector, gently push the terminals until they are firmly seated in the 16-pin connector. After
each terminal has been pushed into the housing, gently pull on the wire to ensure it is locked into place.
3. Check wires in the plug to make sure none are broken at the terminal pin crimp. Repair or replace as
required.
4. Check the wire colors of each wire and make sure that the colors for each pin position match the wire
colors in the wiring diagram.
See Wiring Diagram on page 21-2.
5. When connecting the 16-pin connector to the controller, push plug into controller receptacle with enough
force to lock plug into place. An audible click will be heard when plug is properly seated to the controller.
A procedure is provided for testing each of the wires in the 16-pin connector. Refer to the following chart for
the appropriate procedure for each pin in the 16-pin connector.
If the results of any of the referenced procedures are different from those described in the procedure, check
the continuity of the wires in the wire harness and test the connected components with the appropriate test
procedures.
See Index of Test Procedures on page 21-10.
SPEED CONTROLLER 16-PIN CONNECTOR WIRE
TEST PROCEDURE
Pin 1 – White (18-gauge)
Test Procedure 9A – Pins 1, 2, and 3 on page 21-19
Pin 2 – Yellow (18-gauge)
Pin 3 – Purple/White (18-gauge)
Pin 4 – Green/White (18-gauge)
Reserved for future use. Wire serves no function at this time
Pin 5 – Light Blue (18-gauge)
Test Procedure 9B – Pin 5 on page 21-20
Pin 6 – Green (18-gauge)
Test Procedure 9C – Pin 6 on page 21-21
Pin 7 – Orange/White (18-gauge)
Test Procedure 9D – Pin 7 on page 21-22
Pin 8 – Brown (18-gauge)
Test Procedure 9E – Pins 8 and 16 on page 21-23
Pin 9 – Gray (18-gauge)
Test Procedure 9F – Pin 9 on page 21-24
Pin 10 – Tan (18-gauge)
Test Procedure 9G – Pin 10 on page 21-26
Pin 11 – Open (no wire)
Pin 12 – Blue/White (18-gauge)
Test Procedure 9H – Pin 12 on page 21-27
Pin 13 – Black/White (18-gauge)
Test continuity of each wire and perform
Test Procedure 13 – Motor Speed Sensor on page 21-29
Pin 14 – Light Green (18-gauge)
Pin 15 – Red (18-gauge)
Pin 16 – Blue (18-gauge)
Test Procedure 9E – Pins 8 and 16 on page 21-23
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