B
80
Repair and Service Manual
ELECTRICAL SYSTEM
Read all of SAFETY and this section before attempting any procedure. Pay particular attention to Notices, Cautions, Warnings and Dangers.
699327
Fig. 9 Headlight Assembly
Controller Replacement
Tool List
Qty.
Socket, 7/16” ............................................................... 1
Socket, 10mm.............................................................. 1
Wrench, 7/16” .............................................................. 1
Wrench, 10mm ............................................................ 1
Ratchet ........................................................................ 1
Torque Wrench, in. lbs. ............................................... 1
To prevent electrical shock, the
negative (-) wire must be removed
before discharging the controller.
Use a large screwdriver to cause a short-circuit in the
positive (+) and negative (-) terminals of the
controller. Be sure to hold the screwdriver by the
insulated handle.
NOTICE: Record the location of the wiring on the
controller before disconnecting it.
NOTICE: Always test the motors for a shorted condi-
tion before installing a new controller. An electrical
motor short may be the cause of the controller fail-
ure and will damage the new controller (See AC
Motor Bench Test on page 151).
1.
Use an insulated wrench to disconnect the negative
(-) battery terminal.
2.
Disconnect the main harness from the controller (20)
(Ref Fig. 10).
3.
Remove the bolts (8) and lock washers (7) securing
the wires from the battery and motor to the controller.
Be sure to label the wires so they can be installed in
the origin al location (Ref Fig. 11).
4.
Remove the bolts (6) and lock nuts (9)securing the
controller to the battery tray.
Assemble in the reverse order of removal using new lock
nuts. Tighten the bolts (8) and lock nuts (9) to the torque
values below.
Fig. 10 Controller
Fig. 11 Controller Wiring
4
15
Item
Torque Specification
8, 9
50 - 55 in. lbs. (5.6 - 6.2 Nm)
6
7
8
9
20
Front of Vehicle
Blue U
Wire From
Motor
Yellow V
Wire From
Motor
Green W
Wire From
Motor
Red B+ Wire
From
Solenoid
Black B- Wire
From
Battery
Main Control
Harness
PRELIMINARY
