Pioneer 1200 Maintenance Service Manual page 166

11
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400 ENGINE
Test Procedure 28 – Light Switch, Continued:
7. With the light switch in the OFF position, the reading should be zero volts. With the light in the ON posi-
tion, the reading should be between 11 and 12.5 volts. If the there is no voltage reading, check continuity
of the 10-gauge red wire from the fuse block to the solenoid. Check continuity of the 14-gauge yellow wire
from the light switch to the fuse block. Check the fuse. See Test Procedure 2 – Fuse on page 11-23. If
the headlight diode is functioning correctly, the wires and fuse show continuity and the readings are still
incorrect, replace the switch. See Light Switch Removal, Section 12, Page 12-28.
TEST PROCEDURE 29 – VOLTAGE LIMITER
See General Warning, Section 1, Page 1-1.
1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock
the wheels.
2. Disconnect the battery cables as instructed (Figure 11-1, Page 11-5). See WARNING "To avoid unin-
tentionally starting..." in General Warning, Section 1, Page 1-2.
3. Remove the center dash assembly. See Key Switch Removal, Section 12, Page 12-14.
4. Use a multimeter set on 20 volts DC and connect the red (+) probe to the light switch terminal with the
yellow wire (Figure 11-57, Page 11-47).
5. Loosen the black wire connector (on the end of the long black wire) at the voltage limiter assembly just
enough to maintain the connection and yet expose part of the metal terminal in the connector. Place
black (–) probe on the connector (Figure 11-57, Page 11-47). See following CAUTION.
∆
CAUTION
• Before connecting battery cables, make sure no electrical components touch the front body
trim or other parts of the vehicle frame. Place a dry towel between the body trim and the
center dash to prevent an electrical short circuit.
6. Connect the battery cables, positive (+) cable first, and tighten terminals to 20 ft-lb (27 N·m). Coat ter-
minals with Battery Terminal Protector Spray (CCI P/N 1014305).
7. Pull the light switch to the ON position. The reading should be 11-12 volts. If the there is no voltage read-
ing, check continuity of the 16-gauge black wire from the headlight to the voltage limiter. Check continuity
of the 16-gauge black wire from voltage limiter to the vehicle frame. If the wires show continuity and the
readings are still incorrect, replace the voltage limiter . See Voltage Limiter Removal, Section 12,
Page 12-27.
8. With the Forward/Reverse handle in the NEUTRAL position and the wheels chocked, start the engine
and depress the accelerator pedal to the floor.
9. Push the light switch to the OFF position. The reading should be 14.7-15.3 volts.
10. Pull the light switch to the ON position. The reading should be 11-13 volts. If the reading does not drop
from 14.5-15.5 volts to 11-13 volts, replace the voltage limiter.
TEST PROCEDURE 30 – VOLTAGE AT HEADLIGHT SOCKET
See General Warning, Section 1, Page 1-1.
NOTE: Keep the battery connected while performing this test procedure.
1. Turn the key switch OFF and remove the key. Place the Forward/Reverse handle in NEUTRAL. Chock
the wheels.
2. Inspect wires at the light bulb socket. Make sure wires are securely fastened to the contacts inside
socket.
Page 11-46 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
Test Procedures