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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 the Battery (Sealed Batteries)

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 allow direct metal contact across battery posts.

• Remove negative cable first when disconnecting.

• Install negative cable last when connecting.

NOTE: Do not attempt to open, add fluid or service battery. Any attempt to do so will void warranty.

• Keep battery and terminals clean.

• Keep battery bolts tight.

• Keep small vent holes open.

IMPORTANT: Avoid damage! This battery comes fully charged. If the machine is not used by the service expiration date indicated on the battery, charge the battery.


• Recharge, if necessary, at 6-10 amperes for 1 hour.

Removing and Installing Battery

Removing

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

2. Raise passenger seat.


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3. Disconnect all black negative cables (A) from battery first.

4. Slide back rubber protective cover (B) and disconnect all red positive cables.

5. Loosen hardware (C) that secures battery hold-down (D) and pivot hold-down away from battery.

6. Lift battery from vehicle.

Installing

1. Install battery into vehicle with negative (-) terminal positioned toward front of vehicle and the battery seated properly in the battery tray.

2. Pivot battery hold-down firmly against battery and tighten retaining hardware to secure.

3. Connect all red positive cables to positive (+) battery terminal first. Tighten the connections.

4. Connect all black negative cables to negative (-) battery terminal. Tighten the connections.

5. Apply petroleum jelly to battery terminals to help prevent corrosion.

6. Slide protective cover down the battery positive cable and seat it over the positive (+) terminal.

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.

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 Headlight Bulb

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

2. Locate headlight housing under the front fender.

c CAUTION: Avoid injury! Halogen light bulb contains gas under pressure. The bulb may shatter if the glass is scratched or dropped. Wear eye protection and handle bulb with care when replacing.

IMPORTANT: Avoid damage! Do not touch glass portion of new bulb with bare skin. Contact with oils or dirt will reduce bulb life. Handle bulb by the base or with a clean cloth or gloves.



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3. Rotate bulb socket (A) 1/8 of a turn counterclockwise and remove socket from housing.

4. Disconnect wire connector (B) from socket. Discard the bulb/socket assembly.

5. Connect wiring connector to new bulb/socket assembly. Install the assembly into housing and rotate 1/8 turn to lock in place.

6. Test head lamp function.

Replacing Instrument Panel Bulbs

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

2. Open hood.

3. Remove storage tray.


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4. Reach under instrument panel and remove appropriate bulb socket (A) from plastic housing.

• Rotate bulb socket 1/3 turn.

• Pull socket straight outward.

5. Remove bulb from socket. Discard bulb.

6. Install new bulb in socket.

7. Align and insert bulb socket into plastic housing. Turn socket 1/3 turn to lock in place.

8. Install storage tray.

9. Close hood.

Servicing the Alternator Belt

c CAUTION: Avoid injury! Rotating parts can catch fingers, loose clothing, or long hair. Wait for engine and all moving parts to stop before leaving operator’s station to adjust or service machine.

Checking Belt Tension

1. Park machine safely. (See Parking Safely in the SAFETY section.) Allow engine to cool.

2. Raise and secure cargo box.


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3. Remove hardware (A). Lift belt guard (B) from vehicle.


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4. Apply moderate thumb pressure to belt halfway between pulleys (C). Belt should deflect approximately 9 mm (3/8 in.).

5. Adjust belt tension if deflection is more or less than specified.

6. Replace fan belt if worn or damaged.

Adjusting Belt Tension


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1. Loosen adjusting bolt (D).

2. Loosen mounting bolt (E).

3. Apply outward pressure to alternator housing until tension is correct.

4. Tighten bolts.

5. Check belt tension.

6. Install belt guard and tighten hardware completely.

7. Lower the cargo box.

Replacing Belt

NOTE: Replace alternator belt if excessive wear, damage or stretching is detected.

1. Park machine safely. (See Parking Safely in the SAFETY section.) Allow engine to cool.

2. Tip passenger seat forward.

3. Disconnect black negative (-) cable from battery.

4. Raise and secure cargo box.

5. Remove belt guard hardware. Lift belt guard from vehicle.

6. Loosen alternator adjusting bolt.

7. Loosen alternator mounting bolt.

8. Apply inward pressure to alternator housing.

9. Remove belt from alternator sheave, coolant pump sheave and crankshaft sheave.

10. Install new belt onto sheaves.

11. Apply outward pressure to alternator housing until tension is correct.

12. Tighten mounting and adjusting bolts.

13. Check belt tension. Adjust as necessary.

14. Install belt guard and tighten hardware completely.

15. Connect black negative (-) cable to battery.

16. Lower the cargo box.

17. Lower the seat.

Checking and Replacing Fuses

The fuse block is located under the dash to the left of the brake pedal.

IMPORTANT: Avoid damage! The electrical system may be damaged if incorrect replacement fuses are used. Replace the bad fuse with a fuse of the same amp rating.


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


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2. Fuse identification:

Position

Circuit

Fuse Size

1

Rear Attachments Circuit

40 amp

2

Charging Circuit

30 amp

3

Cooling Fan Motor Circuit

25 amp

4

Starting Motor Solenoid Circuit

30 amp

5

Accessory Power Plug

10 amp

6

Ignition Switch ON Circuit‘

15 amp

7

Front Attachments Circuit

40 amp

8

Open


3. Pull fuse from fuse block (A).

4. Check visually for broken filament in fuse.

5. Push new fuse of correct amp rating into proper position in fuse block.