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Service Electrical


Service the Battery Safely



c CAUTION: Avoid injury! Battery electrolyte contains sulfuric acid. It is poisonous and can cause serious burns:

• Wear eye protection and gloves.

• Keep skin protected.

• If electrolyte is swallowed, get medical attention immediately.

• If electrolyte is splashed into eyes, flush immediately with water for 15-30 minutes and get medical attention.

• If electrolyte is splashed onto skin, flush immediately with water and get medical attention if necessary.

The battery produces a flammable and explosive gas. The battery may explode:

• Do not smoke near battery.

• Wear eye protection and gloves.

• Do not allow direct metal contact across battery posts.

• Remove negative cable first when disconnecting.

• Install negative cable last when connecting.

Checking Battery Electrolyte Level

NOTE: Add only distilled water to replace battery electrolyte.

1. Park the machine safely. (See Parking Safely in the SAFETY section.)

NOTE: Not necessary to remove battery if cargo bed and/or attachment is not installed.

2. Remove battery from vehicle and set it on a level surface.

3. Wash battery with solution of four tablespoons of baking soda to one gallon of water. Be careful not to get the soda solution into the cells. Rinse the battery with plain water and dry.

4. Remove battery cell caps. Make sure cap vents are not plugged.


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5. Check electrolyte level. Electrolyte (B) should be approximately halfway between bottom of filler neck (A) and top of plates (C).

IMPORTANT: Avoid damage! Do not overfill battery. Electrolyte can overflow when battery is charged and cause damage.


6. Add only distilled water if necessary.

7. Install battery cell caps.

Cleaning Battery and Terminals

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Disconnect and remove battery.

3. Wash battery with solution of four tablespoons of baking soda to one gallon of water. Be careful not to get the soda solution into the cells.

4. Rinse the battery with plain water and dry.

5. Clean terminals and battery cable ends with wire brush until bright.

6. Install battery.

7. Attach cables to battery posts using washers and nuts.

8. Apply general purpose grease or silicone spray to terminal to prevent corrosion.

Replacing Battery

NOTE: The service battery is slightly deeper and will need to have the battery bracket moved out. The battery bracket has two sets of mounting holes.


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1. Remove battery (A) from bracket (B).

2. Remove hardware (C) from both sides and bottom of bracket.

3. Slide bracket (B) out to the other hole in bracket to allow the deeper service battery to fit.

4. Install hardware removed earlier and tighten.

5. Install battery.

Using Booster Battery

c CAUTION: Avoid injury! The battery produces a flammable and explosive gas. The battery may explode:

• Do not smoke or have open flame near battery.

• Wear eye protection and gloves.

• Do not jump start or charge a frozen battery. Warm battery to 16?C (60?F).

• Do not connect the negative (-) booster cable to the negative (-) terminal of the discharged battery. Connect at a good ground location away from the discharged battery.


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A - Booster Battery

B - Disabled Vehicle Battery

1. Connect positive (+) booster cable to booster battery (A) positive (+) post (C).

2. Connect the other end of positive (+) booster cable to the disabled vehicle battery (B) positive (+) post (D).

3. Connect negative (–) booster cable to booster battery negative (–) post (E).

IMPORTANT: Avoid damage! Electric charge from booster battery can damage machine components. Do not install negative booster cable to machine frame. Install only to the engine block.

Install negative booster cable away from moving parts in the engine compartment, such as belts and fan blades.


4. Connect the other end (F) of negative (–) booster cable to a metal part of the disabled machine engine block away from battery.

5. Start the engine of the disabled machine and run machine for several minutes.

6. Carefully disconnect the booster cables in the exact reverse order: negative cable first and then the positive cable.

Replacing Stoplight/Taillight Bulb

1. Park vehicle safely. (See Parking Safely in the Safety section.)


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2. Remove two screws (A).


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3. Remove attaching hardware (B) and lens (C) from the combination stoplight/taillight assembly.

4. Remove defective bulb.

• Rotate bulb counterclockwise approximately 1/3 turn and remove from the socket.

5. Install new bulb into the socket.

• Push down top of bulb and rotate clockwise into a locked position.

6. Check operation of lights.

7. Install lens.

Replacing Indicator Light Bulb

1. Park vehicle safely. (See Parking Safely in the Safety section.)

2. Remove front grille.

NOTE: Instrument panel housing removed for photo clarity.


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3. Locate rear of instrument panel housing (B).

4. Remove rubber plugs (C) to locate indicator light bulb assemblies.


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5. Remove defective bulb assembly (D) from the instrument panel housing.

• Rotate bulb assembly counterclockwise approximately 1/3 turn and remove from the housing socket.

6. Install new bulb assembly into housing socket and rotate clockwise into a locked position.

7. Check operation of lights.

8. Install rubber plug.

9. Install front grille.

Replacing Headlight Bulb

1. Park vehicle safely. (See Parking Safely in the Safety section.)

2. Locate headlight housing under the vehicle dash.


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3. Rotate bulb assembly (A) counterclockwise approximately 1/3 turn and remove from the socket.

IMPORTANT: Avoid damage! Do not touch glass headlight bulb with bare skin or bulb may fail prematurely. Use gloves or a cloth when inspecting or replacing the bulb.



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4. Disconnect wiring harness (B) from the bulb assembly.

5. Connect wiring harness to the replacement bulb assembly (A).

6. Install new headlight bulb assembly into housing socket and rotate into a locked position.

7. Check operation of lights.

Checking and Replacing Fuses

IMPORTANT: Avoid damage! Prevent vehicle electrical circuit damage. Make sure replacement fuse is the correct size.


1. Park vehicle safely. (See Parking Safely in the Safety section.)

2. Remove front grille.

3. Fuse identification:


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• 25 amp fuse (A) - Light Circuit

• 10 amp fuse (B) - Starter Circuit

4. Replace defective fuse.

• Remove defective fuse from fuse holder.

• Push in a new fuse.

5. Install front grille.