Troubleshooting
8-20
ELECTRICAL TESTING
This section describes basic electrical testing and test equipment use.
Preliminary Checks and Precautions
Refer to the color wiring diagrams at the end of the manual for component and
connector identification; Use the wiring diagrams to determine how the circuit should
work by tracing the current paths from the power source through the circuit components
to ground. Also, check any circuits that share the same fuse (if used), ground or switch.
If the other circuits work properly and the shared wiring is good, the cause must be in
the wiring used only by the suspect circuit. If all related circuits are faulty at the same
time, the probable cause is a poor ground connection or a blown fuse (if used).
As with all troubleshooting procedures, analyze typical symptoms in a systematic
manner. Never assume anything and do not overlook the obvious like a blown fuse or
an electrical connector that has separated. Test the simplest and most obvious items
first and try to make tests at easily accessible points on the UTV.
Before starting any electrical troubleshooting, perform the following:
1. Check the fuse if the fuse is blown, replace it.
2. Inspect the battery. Make sure it is fully charged, and the battery leads are clean and
securely attached to the battery terminals.
3. Disconnect each electrical connector in the suspect circuit and make sure there are
no bent terminals in the electrical connector
4. Make sure the terminals on the end of each wire are pushed all the way into the
connector. If not, Carefully push them in with a narrow blade screwdriver
5. Check the wires where they connect to the terminals for damage
6. Make sure all terminals within the connector are clean and free of corrosion. Clean
Them, if necessary. And pack the connectors with dielectric grease.
7. Push the connectors with dielectric grease. The connectors are fully engaged and
locked together.
8. Never pull the electrical wires when disconnecting an electrical connector-pull only on
The connector.
Intermittent Problems
Intermittent problems are problems that do not occur all the time and can be difficult to
locate. For example: When a problem only occurs when the UTV is ridden over rough
roads (vibration) or in wet conditions (water penetration), it is intermittent. To locate and
repair intermittent problems, Simulate the condition when testing the components. Note
the following:
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