Section 6

TROUBLESHOOTING FLOWCHARTS

Problem 10 – 7.5A (F1) Fuse Blowing

INSTALL NEW 7.5 AMP FUSE

FUSE BLOWS UPON

INSTALLATION

CHECK THAT FUSE

HOLDER IS NOT

GROUNDED

PASS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FAIL

 

REPLACE HOLDER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

REMOVE WIRE 15

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FROM JI HARNESS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONNECTOR.

 

 

 

 

 

 

 

 

 

 

 

 

 

DOES FUSE BLOW?

 

 

 

 

 

REPLACE

NOTE A:

 

 

 

 

 

 

(SEE NOTE A)

 

NO

 

 

 

 

 

 

 

 

 

 

 

PRINTED CIRCUIT

Disconnect harness from engine controller

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BOARD

circuit board.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Gently bend red tabs outward and remove red

 

 

 

 

 

 

 

YES

 

 

 

 

 

 

 

 

plastic pin guide.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Using a small flathead screwdriver, slide black

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

retainer tabs out away from Wire 15 pin

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(orange).

 

 

 

 

 

 

 

 

 

CHECK WIRE 15

 

 

 

 

 

Gently push pin out of harness and pull wire

 

 

 

 

 

 

 

 

FOR SHORT TO

 

 

 

out from back of plug, noting it’s location for

 

 

 

 

 

 

 

 

GROUND

 

 

 

reinstallation later.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Replace red pin guide and plug J1 harness

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

back into engine controller circuit board.

FUSE IS GOOD BUT

 

 

 

 

 

 

CHECK REMOTE

 

Replace fuse.

 

 

 

 

 

 

 

 

If fuse does not blow, replace engine controller

BLOWS WHEN START-

 

 

 

 

 

 

HARNESS WIRE 15

 

 

 

 

 

 

 

 

circuit board.

 

STOP SWITCH IS

 

 

 

 

 

 

FOR SHORT TO

 

 

 

 

 

 

 

 

 

If fuse still blows, continue to next section of

 

PRESSED

 

 

 

 

 

 

 

 

GROUND

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Problem 10 flow chart.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PERFORM RESISTANCE TESTS ON FUEL PUMP, FUEL SOLENOID,

DISCONNECT JI HARNESS

 

 

 

 

YES

 

CHOKE HEATER AND REMOTE HARNESS WIRE 14 (SEE * BELOW).

FROM ENGINE CONTROL-

 

 

 

 

 

ALSO CHECK WIRE 14 TO EACH COMPONENT FOR SHORT TO GROUND.

LER CIRCUIT BOARD AND

 

 

 

 

 

 

 

 

CHECK WIRE 14 FOR

 

 

 

* CHECK FOR CONTINUITY TO FRAME GROUND. CONNECT ONE TEST

SHORT TO GROUND.

 

 

 

 

 

 

LEAD TO THE POSITIVE WIRE FOR EACH COMPONENT. CONNECT THE

IS CONTINUITY PRESENT?

 

 

 

 

 

 

OTHER TEST LEAD TO FRAME GROUND. RESISTANCE SHOULD BE

 

 

 

 

 

 

 

 

 

 

MEASURED. IF CONTINUITY “0” IS MEASURED TO GROUND, THAT

 

 

 

 

 

COMPONENT OR WIRE IS SHORTED.

 

 

 

 

 

ALSO, REFER TO THE INDIVIDUAL TESTS FOR EACH COMPONENT IN

 

 

 

 

 

SECTION 7, UNDER “PROCEDURE – SHORT TO GROUND”.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

NO

REPLACE COMPONENT OR WIRE

CHECK CHOKE SOLENOID AND STARTER CONTACTOR RELAY

STARTER CONTACTOR RELAY PIN LOCATION J1-1 TEST TO GROUND

CHOKE SOLENOID PIN LOCATION J1-2

TEST TO GROUND

FAIL

FAIL

CHECK WIRE 56 FOR SHORT TO GROUND

CHECK WIRE 90 FOR SHORT TO GROUND

REPAIR OR

REPLACE COMPONENT OR WIRE

Page 35

Page 37
Image 37
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