ACCESSORY CUT RELAY (2003-04)
- Locate and remove accessory cut relay. (Scheme 4)
- Using an ohmmeter, check that there is continuity across terminals 1 and 2. (Scheme 5), Continuity Test. Continuity should not exist across terminals 3 and 5. Check that there is continuity between terminals 3 and 4. If the relay does not operate as specified, replace relay.
- Apply battery voltage across terminals 1 and 2. Using an ohmmeter, check that there is no continuity between terminals 3 and 4. (Scheme 5), Operation Test. Using ohmmeter, check that there is continuity between terminals 3 and 5. If the relay does not operate as specified, replace relay.
- If relay operates as specified, reinstall relay.
Scheme 4
Scheme 5
Scheme 6
- Locate and remove starter relay. Starter relay is marked "ST". See «COMPONENT LOCATIONS»(ref-168684-S29708309632004111500000). Using ohmmeter, verify continuity exists between relay terminals No. 3 and 4. (Scheme 6) See STEP 1. Continuity should not exist between terminals No. 1 and 2. If continuity is not as specified, replace relay.
- Check relay operation by applying battery voltage to terminals No. 3 and 4. (Scheme 6) See STEP 2. Continuity should now exist between terminals No. 1 and 2. If relay does not test as indicated, replace relay.
2003-04
- Remove starter relay. See «COMPONENT LOCATIONS»(ref-168684-S29708309632004111500000).
- Check for continuity between starter relay terminals No. 1 and 2. (Scheme 7) Continuity should exist. If continuity does not exist, replace relay.
- Check for continuity between starter relay terminals No. 3 and 5. Continuity should not exist. If continuity exists, replace relay.
- Apply battery voltage across starter relay terminals No. 1 and 2. Check for continuity between starter relay terminals No. 3 and 5. Continuity should exist. If continuity does not exist, replace relay.
Scheme 7
BRUSHES
- Using a vernier caliper, measure brush length. See «STARTER SPECIFICATIONS»(ref-168684-S12749083152004111500000) . If brush length is less than minimum specification, replace brush holder and field frame.
- Using a pull scale, note brush spring tension the instant the brush spring separates from brush. See «STARTER SPECIFICATIONS»(ref-168684-S12749083152004111500000) . If brush spring tension is less than minimum specification, replace brush springs.
2002
For 2002 model, see STARTER CIRCUIT under STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.
2003
For 2003 model, see STARTER CIRCUIT under STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.
2004
For 2004 model, see STARTER CIRCUIT under STARTING/CHARGING in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.