5-12
Regulator/Rectifier
The regulator/rectifier is located under the driver’s
seat next to the battery. Try to verify all other charg-
ing system components before the regulator/rectifier
is replaced.
TESTING
1. Start engine and warm up to normal operating
temperatures; then connect a multimeter (set at
the DC Voltage position) to the battery as fol-
lows.
2. Connect the red tester lead to the positive bat-
tery post and the black tester lead to the negative
battery post.
3. Slowly increase RPM. The voltage should
increase with the engine RPM to a maximum of
15.5 DC volts.
NOTE: If voltage rises above 15.5 DC 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/
Start-in-Gear/
2WD 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 module and wiring harness are not a
serviceable component and must be replaced as
an assembly.
Headlights
The connectors are the four 2-prong ones secured to
the headlight bulbs (two on each side).
VOLTAGE
NOTE: The low beams are the outside bulbs
(black and white wires) and the high beams are the
inside bulbs (yellow and black wires). Always con-
nect the black tester lead to the black wires. The
ignition switch must be in the ON position.
1. Set the meter selector to the DC Voltage posi-
tion.
2. Set the light switch to the correct position for the
affected light; then connect the black tester lead
to the black wire using a MaxiClip (p/n
0744-041).
3. Connect the red tester lead to the yellow wire
(high beam) or white wire (low beam) using a
MaxiClip (p/n 0744-041). The meter must show
battery voltage.
NOTE: If battery voltage is not shown in any test,
inspect the LIGHTS fuse on the power distribution
module, headlight switch, ignition switch, switch
connectors, or wiring harness.
Taillight-Brakelight
VOLTAGE (Taillight)
NOTE: Perform this test at the socket end of the
taillight-brakelight harness (pigtail). The ignition
switch must be in the ON position and either high
beam or low beam selected on the light switch.
1. Set the meter selector to the DC Voltage posi-
tion.
2. Connect the black tester lead to the black wire;
then connect the red tester lead to the white
wire. The meter should show battery voltage.
3. With the ignition key in the LIGHTS position,
the meter must show battery voltage.
NOTE: If battery voltage is not shown and the
headlights are illuminated, inspect the three-wire
connector in the left-rear canopy tube at the junc-
ture of the canopy tube and lower frame. If battery
voltage is shown on the meter, replace the bulb.
VOLTAGE (Brakelight)
NOTE: Perform this test at the socket end of the
taillight/brakelight harness (pigtail). The ignition
switch must be in the ON position.
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