ELECTRICAL COMPONENTS & WIRING
Page K-7
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
REPLACING ELECTRICAL COMPO-
NENTS
Run / Tow Switch
(Ref Fig. 16 on page K-7)
Tool List
Qty.
Notched Pry Bar.......................................................... 1
Torx Bit 27 IP............................................................... 1
Wire Cutters ................................................................ 1
Wire Stripper ............................................................... 1
Wire Terminal Crimping Tool ....................................... 1
Insulated Wrench, 9/16" .............................................. 1
Using an insulated wrench, disconnect the bat-
tery cable at the negative (-), BL-, battery ter-
minal.
To access the splash shield where the run/tow switch is
mounted, raise and remove the seat bottom. The splash
shield is mounted over the controller on the passenger
side of the vehicle.
1. Disconnect the battery cable at the negative (-) battery
terminal using an insulated wrench.
2. Remove three plastic rivets securing the controller
splash shield; two on the rear body and one from con-
troller heat sink, raise splash shield and turn over to
expose the switch and wires.
3. Remove the seal and upper nut to allow the switch to
be removed from the splash shield.
Check the Run /
Tow label, if it has become difficult to read replace
it with a new one available from service parts.
4. Cut the wires from the existing run/tow switch close to
the switch.
5. Strip insulation from the end of each wire, using a butt
splice connector and heat shrink tubing connect the
wires from the new run/tow switch to the wire harness.
6. Remove the upper nut and seal (7) from the new
switch (8).
7. Install the switch (8) with the notch towards the RUN
direction.
8. Install the upper nut and seal (7) finger tight and
torque as specified in the torque table.
Fig. 16 Run / Tow Switch
9. Install the splash shield using three plastic rivets to
secure the shield to the body and the controller.
Replace any worn or damaged hardware with new as
required
Reverse Warning Indicator
(Ref Fig. 17 on
page K-8)
Tool List
Qty.
Notched Pry Bar ..........................................................1
Torx Bit 27 IP ...............................................................1
Wire Cutters.................................................................1
Wire Stripper................................................................1
Wire Terminal Crimping Tool........................................1
Insulated Wrench, 9/16"...............................................1
Using an insulated wrench, disconnect the bat-
tery cable at the negative (-), BL-, battery ter-
minal.
To access the splash shield containing the run/tow
switch raise and remove the seat bottom.
1. Disconnect the battery cable at the negative (-), BL-,
battery terminal using an insulated wrench.
2. Remove three plastic rivets securing the controller
splash shield; two on the rear body and one from con-
troller heat sink, raise splash shield and turn over to
expose the reverse warning indicator and wires.
ITEM
TORQUE SPECIFICATION
7
13 in. lbs (1.5 Nm) Max.
DO NOT
alter or tamper with this unit. Unauthorized modifications can result in
SERIOUS INJUR
Y or damage to the vehicle and will void the warranty
.
WAIT
30 seconds after reconnecting batteries BEFORE turning key switch to
‘REVERSE’, ‘FOR
WARD’
or ‘NEUTRAL
’ positions.
TOWING -
Always select ‘T
OW’
position before towing
612594
T o disable electrical system, turn key switch to ‘OFF’
and remove battery wires.
ALW
AYS turn key to ‘OFF’
before disconnecting or reconnecting
battery wires. ELECTRICAL
ARC or BA
TTER
Y EXPLOSION can
occur if key is not in the ‘OFF’
position.
5
7
