ELECTRICAL COMPONENTS & WIRING
Page K-13
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notices, Cautions, Warnings and Dangers.
B
B
brake light harness from the accessory harness then
remove the OPS, upper and lower rocker panels, the
floormat, the front cowl, the top portion of the cup holder
and the seat bottom. See the Weather Protection Sec-
tion and the Body Section in this manual for instructions
on removal and replacement of these items.
1. Using an insulated wrench disconnect the accessory
harness from the battery pack, both positive (+) and
negative (-) terminals.
2. Unplug wires going to the headlights, turn signals,
headlight switch, turn signal switch, horn and the
brake lights.
3. Remove the christmas tree rivet holding the brake
switch relay in place on the front splash shield tab that
extends into the cup holder.
4. Unplug the accessory harness from the main harness.
5. Remove the fuse holder from the controller splash
shield.
6. Disconnect the Fan and the Fan Relay.
7. Disconnect wires from the Fuse Block.
8. Disconnect the green ground wire by removing the
torx head bolt that secures the fuse holder bracket to
the battery tray.
9. Disconnect the DC to DC connector and the Charger
Connector.
10.Remove the screw securing the green wire to the on
board charger.
11. Disconnect the tail light wiring connectors.
12.Remove the two Torx head screws that secure the
front edge of the rear body and seat support frame to
the floorboard.
13.Remove the two Torx head screws along back edge of
the seat opening that secure the rear body to the seat
support.
14.Remove the four Torx head screws; two on each side
that secure the lower edge of the rear body to the
floorboard.
15.Remove the two Torx head screws from the bagwell
that secure the rear body to the rear bumper.
16.Raise the front edge of the rear body several inches
and support it with a block or piece of 2" x 4" wood.
This will allow the harness to be passed between the
rear body and the floorboard.
17.Remove the accessory wiring harness from the vehi-
cle.
18.Install new accessory wiring harness making sure that
it follows the proper path.
a) Starting in the cup holder, route the forward section
of the harness in the tabs on the front splash
shield, making sure that the wires tagged ’Driver
Side’ are routed to the driver’s side of the vehicle
and the wires tagged ’Passenger Side’ are routed
to the passenger side. Secure the wires by routing
them through the splash shield tabs
b) Route the wires for the headlight switch through
the opening in the instrument panel for the head-
light switch.
c) route the wires for the 12 Volt Outlet through the
opening in the upper part of the cup holder.
d) Route the wires for the horn down through the flap
in the front splash shield on the driver’s side of the
vehicle.
e) Route the wires and connector for the horn
between the frame and the under side of the front
splash shield and connect to the horn.
f) Connect the horn button connector to the acces-
sory harness under the cup holder.
g) Position the brake relay (1) on the front splash
shield tab that extends into the cup holder base
and secure with a christmas tree rivet (2)
.
Fig. 23 Brake Light Relay
h) Route the rest of the harness down through the
cup holder, in the floorboard channel and under
the rear body in the floorboard channel along with
the main wiring harness.
Make sure that the har-
ness sets below the level of the floor.
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