ENGINE CUT-OUT SWITCH ON VEHICLE
WITH ELECTRIC STARTER
TEST Running
insulation
Continuity in
STOP position
WIRE COLOR BLACK/YELLOW
and BLACK
BLACK/YELLOW
and BLACK
RESISTANCE O.L. 00.0 to 00.5
VOLTAGE — —
NOTE
Engine cut-out
switch must be
in run position.
Engine cut-out
switch must be
in stop position.
Starting Solenoid
Ensure the solenoid receives electric current
as follows. Using the multimeter FLUKE 111
(P/N 529 035 868), measure the voltage between
the wires, indicate in the following table, when
starting the vehicle. The tether cord must be
installed.
ENGINE TYPES COLOR OF WIRES
ALL SDI ENGINES RED/GREY and
ORANGE/BLACK
ALL POWER TEK
ENGINES
RED/GREEN and
ORANGE/BLACK
ALL OTHER ENGINES RED/GREEN and BLACK
If the solenoid does not properly receive current,
the electronic module can be suspected.
If the solenoid receives current, test it as follows.
– Disconnect battery and starter cables from solenoid.
– Inspect connections and clean as necessary.
– Solenoid condition can be checked with an
ohmmeter. Install probes on large connectors
of solenoid.
– Measure the resistance when current is applied
to small connectors; if it is more than a few
ohms, replace solenoid.
If solenoid tests good, check the electric starter. If
electric starter tests good, the electronic module
can be suspected.
Electrical Cables and Connections
Check all connections, harnesses and wires.
Tighten any loose connections.
Replace any chafed wires.
If wires, harnesses and connections are good,
check the electric starter.
Electric Starter
Remove the tuned pipe and disconnect spark plug
cables.
Using booster cable, carefully supply current from
the battery directly to the starter. Connect the
BLACK cable first. Connect the remaining booster
cable from the battery then to the starter.
If the starter turns, ensure wiring harness and connectors
between battery and starter are in good
condition. If they test good, the electronic module
can be suspected.
If the starter does not turn, check for mechanical
problem in the starter.
Electronic Module
Check the MPEM condition, refer to IGNITION
SYSTEM. For SDI and Power TEK engines, refer
to ENGINE MANAGEMENT.
STARTER REMOVAL
– Disconnect BLACK (-) cable from battery.
– Disconnect RED (+) cable from battery.
WARNING
Always disconnect BLACK (-) cable first and
connect last.
– Remove tuned pipe.
– Disconnect RED cable from starter.
– Disconnect ground cable from starter.
– Remove stabilizer bar clamp to