ELECTRICAL
Page G-6
Repair and Service Manual
Read all of Section B and this section before attempting any procedure. Pay particular attention to all Notes, Cautions and Warnings
STORAGE OF BATTERY
A battery that is removed from service for storage must
be cared for as follows:
For battery removal see ‘Battery Removal’ in Section B.
Charge fully. Cover terminals with petroleum jelly to pre-
vent oxidation (use commercially available battery pro-
tectant when installed in vehicle). Store in a cool place
not below 32° F (0° C) or above 80° F (27° C). Battery
should be charged every 30 days using a 2 amp trickle
charger.
TROUBLESHOOTING
If any DVOM readings indicate a faulty wire, it
is recommended that the condition of the termi-
nals and wire junction be examined. A faulty wire should be
replaced with one of the same gauge and color and wired
between the correct components and wire tied to the harness
bundle. The faulty wire should be cut back close to the harness
and the ends protected with vinyl electrical tape.
In order to effectively troubleshoot the circuits that
include the lighting, brake and gauges, the technician
must be able to use the wiring diagram and a DVOM.
The wiring diagram shows the path followed by a voltage
or signal from its origination point to its destination. Each
wire is indicated by color (Ref Fig. 1 on page G-1).
The technician should use simple logic troubleshooting in
order to reduce the number of steps required to isolate
the problem.
Example 1: If the vehicle will not start and none of the
lights function (or burn dimly) the battery should be
tested before trying to troubleshoot the lighting circuit.
Example 2: If a problem occurs in the lighting circuit that
results in only one of the headlights not working, there is
no reason to check battery wiring or the fuse since it is
obvious that voltage is present. Since bulbs will burn out
over time, the obvious place to start is at the headlight
that is not functioning. If power is present at the connec-
tor and the ground wiring is satisfactory, the only possibil-
ities that exist are a burned out bulb or a poor contact
between the connectors and the headlight.
If power is not present but the other headlight functions,
a wiring problem is indicated between the two headlights.
In some cases where battery voltage is expected, the
easiest way to test the circuit is to set the DVOM to DC
volts and place the negative (-) probe of the DVOM on
the negative battery terminal. Move the positive (+) probe
to each wire termination starting at the battery and work-
ing out to the device that is not working. Be sure to check
both sides of all switches and fuses.
When no battery voltage is found, the problem lies
between the point where no voltage is detected and the
last place that voltage was detected. In circuits where no
voltage is expected, the same procedure may be used
except that the DVOM is set to continuity. Place the neg-
ative (-) probe on a wire terminal at the beginning of the
circuit and work towards the device that is not working
with the positive (+) probe. When continuity is no longer
indicated, a failed conductor or device is indicated.
POWER SUPPLY
Tool List
Qty. Required
DVOM ..........................................................................1
Check for loose or bare wires
If any DVOM readings indicate a faulty wire, it
is recommended that the condition of the termi-
nals and wire junction be examined. A faulty wire should be
replaced with one of the same gauge and color and wired
between the correct components and wire tied to the harness
bundle. The faulty wire should be cut back close to the harness
and the ends protected with vinyl electrical tape.
Check for loose wires at each terminal connection and
for worn insulation or bare wires touching the frame.
Bare wires may cause a short circuit.
Check battery condition
Due to the resistance of the wires involved
within the harness, voltage readings may be
somewhat lower than battery voltage. A reading of 1 volt below
reference battery voltage is acceptable.
Check for adequate battery volts (nominal 12 VDC) by
setting DVOM to the next range above 12 VDC and place
the red probe (+) on the battery post with the green wire
attached. Place the black probe (-) on the battery post
with the black wire attached. A reading of 11 VDC or
greater indicates adequate battery condition. No reading
indicates (a) a poor connection between the probes and
the battery terminals; (b) a faulty DVOM. A voltage read-
ing below 11 volts indicates poor battery condition and
the vehicle should be recharged before proceeding with
the test.
Summary of Contents for ST 4X4
Page 6: ...Page iv Repair and Service Manual TABLE OF CONTENTS Notes...
Page 10: ...Repair and Service Manual SAFETY INFORMATION Page viii Notes...
Page 12: ...GENERAL INFORMATION ROUTINE MAINTENANCE Page A ii Repair and Service Manual Notes...
Page 24: ...SAFETY Page B ii Repair and Service Manual Notes...
Page 34: ...BODY AND TRUCKBED Page C ii Repair and Service Manual Notes...
Page 50: ...BRAKES Page D ii Repair and Service Manual Notes...
Page 68: ...CONTINUOUSLY VARIABLE TRANSMISSION CVT Page E ii Repair and Service Manual Notes...
Page 74: ...DIRECTION AND DRIVE SELECTOR Page F ii Repair and Service Manual Notes...
Page 80: ...ELECTRICAL Page G ii Repair and Service Manual Notes...
Page 114: ...FRONT SUSPENSION AND STEERING Page J ii Repair and Service Manual Notes...
Page 128: ...FUEL SYSTEM Page K ii Repair and Service Manual Notes...
Page 136: ...PAINT Page L ii Repair and Service Manual Notes...
Page 142: ...REAR AXLE AND SUSPENSION Page M ii Repair and Service Manual Notes...
Page 152: ...SPEED CONTROL Page N ii Repair and Service Manual Notes...
Page 160: ...TROUBLESHOOTING Page P ii Repair and Service Manual Notes...
Page 168: ...WHEELS AND TIRES Page R ii Repair and Service Manual Notes...
Page 174: ...GENERAL SPECIFICATIONS Page S ii Repair and Service Manual Notes...
Page 180: ...LIMITED WARRANTY Page T ii Repair and Service Manual Notes...
Page 182: ...Page T 2 Repair and Service Manual LIMITED WARRANTY Notes...