ELECTRICAL SYSTEM AND TESTING: ELECTRIC VEHICLE
Troubleshooting
Page 21-20
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
21
Test Procedure 9B – Pin 5
See General Warning on page 1-1.
Pin 5 in the 16-pin connector provides a connection point for the solenoid lockout circuit from the onboard
computer to the speed controller.
1. Disconnect the battery cables as instructed.
See WARNING “To avoid unintentionally starting...” in
General Warning on page 1-1.
2. Place chocks at the front wheels and lift the rear of the vehicle with a chain hoist or floor jack. Position
jack stands under the frame crossmember between the spring mount and side stringer, just forward of
each rear wheel.
See WARNING “Lift only one end...” in General Warning on page 1-1.
3. Disconnect the 16-pin connector at the speed controller.
4. Set a multimeter to 200 volts DC. Insert the red (+) probe of the multimeter into pin 5 (light blue wire) of
the 16-pin connector.
See following CAUTION.
Using an alligator clip, connect the black (–) probe to the
B– terminal of the speed controller
(Figure 21-6, Page 21-20)
.
CAUTION
• Do not fully insert probes into the 16-pin plug. Doing so can result in a poor connection.
5. Place the Tow/Run switch in the TOW position and connect the battery cables, positive (+) cable first.
Tighten battery terminals to 110 in-lb (12.4 N·m).
6. Place the Tow/Run switch in the RUN position.
7. The multimeter should indicate zero volts DC at this time.
8. While monitoring the multimeter, plug the battery charger into the vehicle charger receptacle.
9. After a short delay, the onboard computer should power-up (come out of sleep mode), charger relay
should click, and the ammeter on the charger should indicate that the vehicle batteries are being
charged.
10. The multimeter should indicate zero volts DC while the charger is connected to the vehicle.\
11. While observing the multimeter, disconnect the DC plug from the vehicle charger receptacle.
Figure 21-6 Pin 5 Test
2m
20
m
200
m
2k
200
200
200
200
20
2
200
m
500
20k
200k
2000
k
1000
OFF
WAVETEK
5XL
V
V
V
A
!
!
COM
200nA
MAX
1000 ---
750V
FUSED
SPEED CONTROLLER
200 DCV SETTING
(READING WITH
OBC POWERED-UP
AND BATTERY CHARGER
DISCONNECTED)
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