Check the voltage regulator
Campaign no.: 2008–0016
October 3, 2008 Subject:REV-XP Wiring Harness Issues
No. 2008-20
PROBLEM
On some of the abovementioned vehicles, electrical
irregularities of an unknown source may be experienced.
SOLUTION
This bulletin gives troubleshooting steps in order
to quickly locate and repair electrical irregularities.
The following repair procedures must be completed
as per this bulletin:
– Voltage Regulator Wires Chafing
– Maintenance on Countershaft Support
– Taillight wires chafing
– Cluster gauge issue.
Voltage Regulator Wires
Chafing
Vehicle Preparation
1. Remove RH side panel from vehicle.
2. Remove muffler springs
3. Removemuffler from vehicle.
4. Remove acoustic panel from vehicle.
Voltage Regulator Wires Repair
1. Inspect voltage regulator wires for chafing or
cutmarks and repair if necessary.
2. Reroute voltage regulator harness toward the
top.
3. Attach voltage regulator harness on oil injection
line using a locking tie
4. Clean rivet area using pulley flange cleaner
5. Apply silicone to cover rivet.
NOTE: Make sure to properly cover the rivet to
eliminate any sharp edges or protrusions that
could damage the voltage regulator wires.
Taillight Wires Chafing
NOTICE Taillight lens is held in place by two
plastic pins inserted in rubber grommets. If
lens is forced too far sideways when removing,
the lensmounting pins may break and lens will
have to be replaced. Do not pull lens out too far
to avoid damaging wiring.
1. Remove taillight lens by carefully pulling on
lens at both ends.
2. Rotate bulb holder counterclockwise to remove
it from lens.
3. Carefully pull taillight harness toward the rear
of vehicle.
NOTE: If the lens does not pull out far enough to
work on, the locking tie for the taillight harness under
the fuel tank may have to be removed and the
harness laid down in the tunnel channel. Refer to
the following steps:
– Remove fuel tank side trim panels.
– Remove fuel tank side retaining nuts.
– Remove fuel tank side shoulder bushings.
– Slightly lift up rear part of fuel tank.
– Cut taillight harness locking tie.
– Stretch taillight harness in the tunnel channel.
– Reinstall fuel tank shoulder bushings.
– Secure fuel tank side retaining nuts to 33 N•m
(24 lbf•ft).
– Reinstall fuel tank side trim panels.
4. Pull protector tube toward the bulb holder to
protectwires.