ELECTRICAL COMPONENTS
Battery
2001 Pioneer 1200 Gasoline Vehicle Maintenance and Service Manual Page 12-31
12
Light Switch Removal
1. Disconnect the battery cables, negative cable (–) first (Figure 12-1, Page 12-2).
2. Loosen the set screw locking the light switch knob (1) to the shaft (Figure 12-32, Page 12-30).
3. Remove the dash panel. See Key Switch Removal on page 12-15.
4. Disconnect the wires from the light switch.
5. Remove the outer nut (2) from the light switch (3) (Figure 12-32, Page 12-30).
6. Remove the light switch from the dash panel.
Light Switch installation
1. Reconnect the wires to the light switch. See Wiring Diagram, Section 11, Page 11-6.
2. Thread the check nut (4) onto the switch until an equal number of threads show on both sides. Insert
the switch through the dash panel and install the nut (2) on the outside of the dash. Tighten the nut to
14 in-lb (1.6 N·m) (Figure 12-32, Page 12-30).
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 dash panel in reverse order of removal.
5. Connect battery cables, positive cable first and tighten the terminals to 20 ft-lb (27.1 N·m). Coat termi-
nals with Battery Protector Spray (CCI 1014305).
BATTERY
Read DANGER and WARNING on page 12-1.
∆ DANGER
• Due to the danger of an exploding battery, wear a full face shield and rubber gloves when
working around a battery.
• Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and
service area. Ventilate when charging or using in an enclosed space. Wear a full face shield
and rubber gloves when working on or near batteries. For added protection, cover top of the
battery when servicing the vehicle.
• Battery – Poison! Contains acid! Causes severe burns! Avoid contact with skin, eyes, or
clothing.
- External: Flush with water. Call a physician immediately.
- Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable
oil. Call a physician immediately.
- Eyes: Flush with water for 15 minutes. Call a physician immediately.
