Pioneer 1200 Maintenance Service Manual page 164

11
TROUBLESHOOTING AND ELECTRICAL SYSTEM: FE400 ENGINE
TEST PROCEDURE 26 – FUEL GAUGE
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 to gain access to the back of the fuel gauge/hour meter. See Key
Switch Removal, Section 12, Page 12-14.
4. Place a sheet of insulating material between the front frame and the electrical connections on the rear
of the center dash assembly to prevent contact between the two.
5. Disconnect the orange wire from the fuel gauge/hour meter.
6. Set a multimeter to 20 volts DC and place the red (+) probe of the multimeter on the positive post of the
battery. Place the black (–) probe on the negative post of the battery. Record the voltage reading.
7. Set a multimeter to 20 volts DC and place the red (+) probe of the multimeter on the (2) terminal of the
fuel gauge/hour meter with the blue wire. Place the black (–) probe on the (3) terminal of the fuel gauge/
hour meter with the black wire (Figure 11-54, Page 11-44).
8. Reconnect the battery cables, positive (+) terminal first, and tighten to 20 ft-lb (27.1 N·m).
9. Turn the key switch ON. The voltage reading should be the same as the battery voltage reading recorded
earlier. If not, check the continuity of the blue and black wires (Figure 11-54, Page 11-44).
10. The orange wire should remain disconnected for this step. With the black probe still on the (3) terminal
of the fuel gauge/hour meter, place the red (+) probe of the multimeter on the (1) terminal of the fuel
gauge/hour meter. The voltage reading should be the same as the full battery voltage reading obtained
in step 6. If the reading is incorrect, replace fuel gauge/hour meter (Figure 11-55, Page 11-44).
Remove 18-gauge
orange wire to
sending unit.
WAVETEK 5XL
V OFF V
1000 500
200
200
20 200
2 2m
200
20
m
m
200
2000
m
k
200k
200
Ω 20k
2k A
Ω
V ! COM ! 200nA
MAX
1000 ---
FUSED
750V
18-GAUGE BLACK
WIRE TO GROUND
Figure 11-54 Fuel Gauge Test
TEST PROCEDURE 27 – HOUR METER
See General Warning, Section 1, Page 1-1.
NOTE: Keep the battery connected while performing this test procedure.
1. Place the Forward/Reverse handle in NEUTRAL. Chock the wheels.
2. Turn the key switch to ON and record the current hour meter reading.
3. Turn the key past the ON position to the START position and hold until the engine is running smoothly.
Release the key and it will return to the ON position and the engine should idle.
Page 11-44 2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual
18-GAUGE
BLUE WIRE
TO NO. 1 ON
KEY SWITCH
18-GAUGE
WHITE WIRE
18-GAUGE
ORANGE
WIRE
WAVETEK 5XL
V
V OFF
1000 500
200 200
20
200
2 2m
200
20
m
m
200
2000
k m
200k
Ω 20k 200
A
2k
Ω
! ! 200nA
V COM
MAX
1000 ---
750V FUSED
Figure 11-55 Fuel Gauge Voltage Test
Test Procedures