Pioneer 1200, Maintenance Service Manual

Page: 196 / 300

ELECTRICAL COMPONENTS: FE400 ENGINE Light Switch
Page 12-28 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
12
Voltage Limiter Installation
1. Mount the voltage limiter to the frame and tighten to 25 in-lb (2.8 N·m) (Figure 12-31, Page 12-27).
2. Connect the black 16-gauge wire from the harness to the negative (–) terminal on the voltage limiter.
3. Install the dash panel in reverse order of removal. See Key Switch Removal on page 12-14.
4. Connect the battery cables, positive (+) cable first, and tighten the terminals to 20 ft-lb (27.1 N·m). Coat
terminals with Battery Terminal Protector Spray (CCI P/N 1014305).
LIGHT SWITCH
See General Warning, Section 1, Page 1-1.
TESTING THE LIGHT SWITCH
See Test Procedure 28, Section 11, Page 11-45.
Light Switch Removal
1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock
the wheels.
2. Disconnect the battery cables as instructed (Figure 12-1, Page 12-1). See WARNING "To avoid unin-
tentionally starting..." in General Warning, Section 1, Page 1-2.
3. Loosen the set screw locking the light switch knob (1) to the shaft (Figure 12-32, Page 12-27).
4. Remove the dash panel. See Key Switch Removal on page 12-14.
5. Disconnect the wires from the light switch.
6. Remove the outer nut (2) from the light switch (3) and remove (Figure 12-32, Page 12-27).
Light Switch installation
1. Connect 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. Install to
the dash panel with nut (2) on the outside of the dash and tighten the nut to 14 in-lb (1.6 N·m)
(Figure 12-32, Page 12-27).
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. See Key Switch Removal on page 12-14.
5. Connect the battery cables, positive (+) cable first, and tighten the terminals to 20 ft-lb (27.1 N·m). Coat
terminals with Battery Terminal Protector Spray (CCI P/N 1014305).
BATTERY
See General Warning, Section 1, Page 1-1.
∆
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.
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