Service Electrical

Battery Statement

WARNING: Battery posts, terminals and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

Cleaning or Replacing Battery

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c CAUTION: Avoid injury! 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.

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

2. Raise cargo box.

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3. Disconnect black negative (-) cables (A) from battery.

4. Slide red positive terminal cover (B) back and disconnect red positive (+) cables (C).

5. Disconnect black rubber hold-down strap (D).

6. Clean battery with a brush or damp cloth. Keep dirt out of battery cells.

NOTE: If a thorough cleaning of the battery and surrounding area is needed, or battery replacement is necessary, remove battery from the utility vehicle.

7. Remove corrosion from battery terminals and cable ends with a wire brush.

8. Clean battery, battery terminals, cable ends, battery box, and other parts with a solution of one part baking soda and four parts water. DO NOT allow solution to enter battery cells.

9. Rinse all parts with clean water and allow to dry.

10. Install battery.


IMPORTANT: Avoid damage! Be sure battery drain tubes are clear and free of obstruction. Drain tubes must be routed through bottom of utility vehicle frame to prohibit damage caused by corrosive battery acid.

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11. Connect red positive (+) cables (E) to battery terminal first. Slide red terminal cover (F) down to cover terminal.

12. Connect black negative (-) cables (G). Make sure connections are tight.

13. Apply petroleum jelly or silicone spray on battery terminals to help prevent corrosion.

14. Install black rubber hold-down strap (H).

15. Lower utility vehicle cargo box.

Checking Battery Electrolyte Level

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.

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

2. Remove battery from vehicle and set it on a level surface.

3. Remove battery manifold cap. Be sure breather tube does not come off cap.


IMPORTANT: Avoid damage! Do not fill cells to the bottom of filler neck (A). Electrolyte can overflow when battery is charged and cause damage.

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4. Electrolyte (B) should be 6 mm (1/4 in.) above plates (C).

5. Add distilled water if necessary.

6. Install manifold cap. Check vent tube is attached to cap and routed down out of vehicle frame.

7. Install battery.

Using Booster Battery

c CAUTION: Avoid injury! The battery produces a flammable and explosive gas. The battery may explode:

· Do not attempt to jump start a frozen battery. Warm to 16 degrees C (60 degrees F).

· Do not smoke near battery.

· Wear eye protection and gloves.

· Keep sparks and flames away.

· 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.


IMPORTANT: Avoid damage! There are two 12 volt batteries connected in parallel. This IS NOT a 24 volt system.

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A - Booster Battery

B - Disabled Vehicle Battery

C - To Second Battery

1. Connect positive (+) booster cable to booster battery (A) positive (+) post (D).

2. Connect the other end of positive (+) booster cable to the disabled vehicle battery (B) positive (+) post (E).

3. Connect negative (-) booster cable to booster battery negative (-) post (F).

4. Connect the other end (G) of negative (-) booster cable to a metal part of the disabled machine frame 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. Remove hood.

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.

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


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.

3. Install new bulb (B) into socket, and install socket into housing.

4. Test head lamp function.


IMPORTANT: Avoid damage! Vibration of hood against headlight housing may cause headlight lamps to fail early. Allow clearance around headlight housings when installing hood.

5. Install hood.

Replacing Headlight Housing

1. Remove hood.

2. Disconnect bulb socket from housing.

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3. Remove screws (A).

4. Install new assembly and install screws.


IMPORTANT: Avoid damage! Vibration of hood against headlight housing may cause headlight lamps to fail early. Allow clearance around headlight housings when installing hood.

5. Install hood.

Replacing Instrument Panel Bulbs

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Picture Note: Hood shown removed for clarity. Removal of hood not required.

1. Reach under dash panel and remove appropriate bulb socket (A) from plastic housing.

· Rotate bulb socket 1/4 turn.

· Pull socket straight outward.

2. Remove bulb from socket. Discard bulb.

3. Install new bulb in socket.

4. Align and insert bulb socket into plastic housing. Turn socket 1/4 turn to lock in place.

Checking and Adjusting Alternator Belt

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

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

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3. Apply moderate thumb pressure to belt halfway between pulleys. Belt should deflect approximately 13 mm (1/2 in.).

4. To adjust belt:

a. Loosen screw and nut (C) and screw (D).

b. Move alternator (E) away from engine to tighten belt or toward engine to loosen belt.

c. Hold alternator in position to maintain proper belt tension. Tighten hardware (C) and (D).

5. Check belt tension again.

6. Replace fan belt if worn or damaged.

7. Install belt guard and tighten hardware completely.