5-16
CDI Unit
The CDI is located beneath the seat near the battery.
NOTE: The CDI unit is not a serviceable compo-
nent. If the unit is defective, it must be replaced.
The CDI is rarely the cause for electrical problems;
however, if the CDI is suspected, substitute another
CDI unit to verify the suspected one is defective.
NOTE: Prior to replacing the CDI unit to assure
the CDI unit is defective, it is advisable to perform
a CDI peak voltage test (see Ignition Coils in this
section) and/or perform a continuity test of the wir-
ing harness from the CDI connector to the CDI
unit.
Regulator/Rectifier
The regulator/rectifier is located under the rear rack
and rear fenders. Try to verify all other charging sys-
tem components before the regulator/rectifier is
replaced.
TESTING
1. Start engine and warm up to normal operating
temperatures; then connect a multimeter to the
battery as follows.
2. Select the D.C. Voltage position; then connect the
red tester lead to the positive battery post and the
black tester lead to the negative battery post.
3. Start the engine and slowly increase RPM. The
voltage should increase with the engine RPM to a
maximum of 15.5 D.C. volts.
NOTE: If voltage rises above 15.5 D.C. volts, the
regulator is faulty or a battery connection is loose
or corroded. Clean and tighten battery connec-
tions or replace the regulator/rectifier. If voltage
does not rise, check Voltage (Charging Coil - No
Load) in this section. If charging coil voltage is
normal, replace the regulator/rectifier.
Neutral Start/Front Drive
Actuator/Start-in-Gear/
Differential Lock
Relays
The relays are indentical plug-in type located on the
power distribution module. Relay function can be
checked by switching relay positions. The relays are
interchangeable.
NOTE: The relay schematic is embossed on the
relay housing for testing continuity.
NOTE: The module and wiring harness are not a
serviceable component and must be replaced as
an assembly.
Headlights
The connectors are the four 2-wire ones secured to the
front bumper supports (two on each side) with cable
ties.
BULB VERIFICATION
(Low and High Beam)
NOTE: Perform this test on each headlight bulb.
Also, a 12-volt external power supply w/jumpers
will be needed.
1. Disconnect the wiring harness from the bulb to be
tested.
2. Connect the power supply (positive) to one bulb
contact; then connect the power supply (negative)
to the remaining bulb contact.
3. The bulb should illuminate.
4. If the bulb fails to illuminate, it must be replaced.
VOLTAGE
NOTE: Perform this test in turn on the main har-
ness side of all four connectors. Also, the ignition
switch must be in the LIGHTS position.
NOTE: The LO beam is the outside bulb, and the
HI beam is the inside bulb.
1. Set the meter selector to the D.C. Voltage position.
2. Connect the red tester lead to one wire; then
connect the black tester lead to the other wire.
3. With the dimmer switch in the LO position, test
the two outside connectors (LO beam). The meter
must show battery voltage.
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