Gas 6x4 Gator Electrical From TM1518

ELECTRICAL COMPONENT LOCATION
Component Location
Component Location - 6X4 Gas
A C
G
J
M56334L F - S2 Key Switch

A - S5 Light Switch G - W2 Main Wiring Harness
B - Instrument Panel Lights H - W4 Standard Headlight Wiring Harness
C - M3 Radiator Fan Motor I - E4 Headlight
D - B3 Radiator Core Temperature Switch J - E3 Headlight
E - Cargo Box Lift Switch (optional)
Electrical Component Location - 274

ELECTRICAL COMPONENT LOCATION
E
D
C
F
B
K
L
M
M56334R G - K1 and K2 Cargo Box Lift Directional Relays

A - M2 Fuel Pump H - M2 Cargo Box Lift Motor
B - N1 Voltage Regulator/Rectifier I - M1 Starting Motor
C - K1 Start Relay J - S1 Neutral Start Switch
D - A1 Ignition Module K - S4 Differential Lock Switch
E - G1 Battery L - S3 Park Brake Switch
F - W17 Cargo Box Lift Wiring Harness M - W2 Main Wiring Harness
Electrical Component Location - 275

ELECTRICAL SCHEMATICS AND HARNESSES - 6X4 GAS
Schematics and Harnesses - 6X4 Gas V1 - Diode (SE1, W2)
V2 - Diode (SE5, W2)
Electrical Schematic and Wiring Harness W1 - Shielded Ground (SE1, W2)
Legend - 6X4 Gas
Connectors:
A1 - Ignition Module (SE3, W2)
X1 - W2 Main Wiring Harness to W8 Engine Wiring
B1 - Left Pulser Coil (SE3, W2) Harness (SE1, W2; SE2, W2; SE3, W2; SE5, W2)
B2 - Right Pulser Coil (SE3, W2) X2 - W8 Engine Wiring Harness to W9 Engine Wiring
B3 - Radiator Core Temperature Switch (SE4, W2) Harness and W13 Engine Wiring Harness (SE3, W2)
B4 - Engine Temperature Switch (SE5, W2) X3 - W9 Engine Wiring Harness to W10 Engine Wiring
Harness (SE3, W2)
B5 - Engine Oil Pressure Switch (SE5, W2)
X4 - W10 Engine Wiring Harness to W11 Engine Wiring
E1 - Spark Plug (SE3, W2)
Harness (SE3, W2)
E2 - Spark Plug (SE3, W2)
X5 - W2 Main Wiring Harness to M3 Radiator Fan Motor
E3 - Right Headlight (SE6, W2) (SE4, W2)
E4 - Left Headlight (SE6, W2) X6 - M3 Radiator Fan Motor to B3 Radiator Core
F1 - Fusible Link (SE1, W2) Temperature Switch (SE4, W2)
F2 - Fusible Link (SE1, W2) X7 - B3 Radiator Core Temperature Switch to W1 Shielded

Ground (SE3, W2)
F3 - Fusible Link (SE1, W2)
X8 - W2 Main Wiring Harness to S5 Cargo Box Lift Kit
G1 - Battery (SE1, W2) Switch (Opt.) (SE5, W2)
G2 - Stator (SE2, W2) X9 - W2 Main Wiring Harness to W17 Cargo Box Lift Kit
G3 - High Capacity Alternator (Optional) (SE2, W2) Wiring Harness (SE5, W2)
H1 - Discharge Light (SE5, W2) X10 - W2 Main Wiring Harness to W4 Standard Headlight
Wiring Harness (SE6, W2; SE2, W18)
H2 - Park Brake Light (SE5, W2)
X11 - W4 Standard Headlight Wiring Harness to W2 Main
H3 - Differential Lock Light (SE5, W2) Wiring Harness (SE6, W2; SE1, W18)
H4 - Engine Coolant Temperature Light (SE5, W2)
X12 - W29 Auxiliary Alternator Wiring Harness to W2 Main
H5 - Engine Oil Pressure Light (SE5, W2) Wiring Harness (SE2, W2)
K1 - Start Relay (SE1, W2) X13 - W29 Auxiliary Alternator Wiring Harness to N1
M1 - Starting Motor (SE1, W2) Voltage Regulator(SE2, W2)
M2 - Fuel Pump (SE4, W2)

M3 - Radiator Fan Motor (SE4, W2)
M4 - Cargo Box Lift Kit Motor (Optional) (SE5, W2)
N1 - Voltage Regulator/Rectifier (SE2, W2)
R1 - Carburetor Heater (SE4, W2)
S1 - Neutral Start Switch (SE1, W2)
S2 - Key Switch (SE1, W2)
S3 - Park Brake Switch (SE5, W2)
S4 - Differential Lock Switch (SE5, W2)
S5 - Cargo Box Lift Kit Switch (Opt.) (SE5, W2)
S6 - Light Switch (SE6, W2)
T1 - Ignition Coil (SE3, W2)
T2 - Ignition Coil (SE3, W2)
Electrical Schematics and Harnesses - 6X4 Gas - 276

W2 Standard Electrical Schematic - 6X4 Gas
W2 Standard Electrical Schematic - 6X4 Gas (1 of 2)
210 Red/Blk or Blu/Blk

401 Yel
710 Pur/Blk
F1 425 Yel
F2 200 Red 400 Yel/Red
215 Red 600 Brn
S1 Neutral 435 Yel
Fusible Start Switch Start W8 Engine
Links Wiring Harness X1
Run
F3 Blk
Neutral Off Yel/Wht E2
X2 Spark
Yel/Wht Yel/Wht
K1 In Blk Plug
Gear S2 Key
Start E1
Relay Switch
Spark
30 85 Plug
302 110 Blk
Org/Wht T1 Ignition Org T2 Ignition
87a 87 86
Coil Coil
115
Blk/ W9 Engine
211 705 Blk Yel
Pur
Wiring
Red 201 W10 Engine Wht Harness
Red 216 706 N1 Voltage Wiring
Red Pur Regulator/ Harness X3 X3 X3
700 Rectifier Blk
Pur
U
V1 Diode A1 Ignition Module
590 595
Brn/Yel Brn/Wht
130 X4 X4 X4 X4
Red X1
X1 X1 Blk Yel Pnk
Grn/ Wht/
Wht Blu
Red
Blk Blk
W12 Engine B2 W11
B S Wiring Harness Left Pulser Engine
G1 G
Coil Harness
Battery
B1
G2 Right Pulser
M1 Stator Coil
M Starting
Blk Motor
205 Red 302 Org/Wht
130 Blk
115 Blk
W1 Shielded
Ground 110 Blk
Battery Cables W2 Main Wiring Harness
Optional Lift Kit Component
SE1 - Starting SE2 - Charging SE3 - Ignition

W2 Standard Electrical Schematic - 6X4 Gas (2 of 2)
X9 To W17 Cargo
Box Lift Kit
210 Red/Blk or Blu/Blk X8 X8 Wiring Harness
670 Yel/Wht
675 Yel/Blk
415
S5 Cargo Box Lift
Yel/Red Kit Switch (Opt.)
425 Yel
X10
400 Yel/Red 410 Yel/Red
600 Brn
402 Yel 400
435 Yel Yel/
420 Red
430 Yel Yel On Off
R1 Carburetor S6
Heater 423 Yel Light
Blk M3 Switch
Off On
Radiator On Off
456 Yel/Wht
Fan 455 Yel/Wht
Motor X5
Blu
W13 S3 Park S4 E3 Right E4
Engine Brake Differential Headlight Left
Wiring M Lock Switch Head-
Switch
Harness light
640 110 Blk
Grn
600 630
Blu
Brn Grn/Blk
W4 Standard Headlight 100
Wiring Harness Blk
H1 W18 or W19 Headlight
H2 H3 Wiring Harness (Opt.)
M2 Discharge Park Brake Differential X11
Fuel M X6 Light Light Lock Light H5 Engine Oil
Pump Pressure Light
+ _
403 Yel
100 105 Blk 125 Blk 120 Blk

Blk Blk H4 Engine
Coolant 302 Org/Wht 620
Temperature Tan
300
Light Org/Wht
W1
t0 B3 Radiator Core 115 X1 V2 X1
Temperature Switch Blk Diode
Yel Blu/Red
Blk
t° t°
X7
135
Blk
B4 Engine Coolant B5
W1 Temperature Switch Engine Oil
302 Org/Wht
Pressure
Switch
115 Blk
105 Blk
110 Blk

SE4 - Fuel Pump and Fan SE5 - Instrumentation SE6 - Lights

W2 Main Wiring Harness - 6X4 Gas
W2 Main Wiring Harness - 6X4 Gas (1 of 2)
K1 Start Relay
N1 Voltage Regulator/Rectifier 705
700
590 130
X1 To W8 Engine 600 425
Wiring Harness 401
435 215
590
595 M2
595 205 Fuel Pump
705
Negative Battery Cable 620 300
700 V1 Diode
100 430
W1 Shielded 105 435
Ground
706
135
130 430
M1 216 215 100

F3
Starting 205
Motor Bolt 211 210
F2
201 200
F1
Positive Battery Cable

670
640
420
675 705 423
X9 To W17 Cargo Box
Lift Kit Wiring Harness 135
710
S1 Neutral Start M3 Radiator
Switch 630
423 Fan Motor 210
430
B3 Radiator
S3 Park Core Temperature
Brake Switch S4 Differential Switch
Lock Switch

W2 Main Wiring Harness - 6X4 Gas (2 of 2)
675
415
H1 Discharge
670 Light 600
125
X8 To S5 Cargo Box 125
Lift Kit Switch (Opt.) H5 Engine Oil
Pressure Light 620
403 402
301
403
V2 H4 Engine Coolant
Temperature 300
302 301
Light
403
402
H2 Park 403
Brake Light 630
120
125
H3 Differential
Lock Light 640
S2 115
120
Key Switch
415
200 302
425 710
410 400
401 110
420 115
400
X10 To W4 Standard Headlight Wiring Harness;

To W18 or W19 Light and Horn Wiring Harness (Opt.)
402
410
X11 To W4 Standard Headlight Wiring Harness;

105 To W18 To W19 Light and Horn Wiring Harness (Opt.)
110

W2 Main Wiring Harness Color Code Table - Circuit Wire Color Termination Points
6X4 Gas Number Size
420 0.8 Yel Solder connection
Circuit Wire Color Termination Points
(400 Yel/Red), S4
Number Size
100 1.0 Blk M2, W1 Gnd 423 0.8 Yel S4, S3
105 1.0 Blk X11, M2 425 1.0 Yel Solder connection

(400 Yel/Red), N1
110 0.5 Blk S2, X11
430 0.8 Yel S3, M2
115 0.5 Blk H3, S2
435 0.8 Yel M2, X1
120 0.5 Blk H2, H3
590, 595 2.0 Brn/Yel N1, X1
125 0.5 Blk H1, H2
600 0.5 Brn N1, H1
130 2.0 Blk N1, W1 Gnd
620 0.5 Tan H5, X1
135 1.0 Blk X7, W1 Gnd
630 0.8 Gry/Blk S3, H2
200 1.0 Red F1, S2
640 0.5 Grn S4, H3
201 0.5 Red- F1 Fuse soldered
Fuse inline; M1, 200 Red 670, 675 1.0 Yel/Wht X8, X9
205 2.0 Red M1, N1 700 2.0 Pur K1, X1
210 1.0 Red/Blk, F2, M3 705 0.8 Pur V1 Diode, S1

or Blu/ 706 0.8 Pur K1, V1 Diode
Blk
710 0.8 Pur/Blk S1, S2
Fuse inline; M1, 210 Red
215 2.0 Red F3, K1
Fuse inline; M1, 215 Red
300 0.5 Org/Wht H4, X1
301 0.5 Diode Soldered inline; 302
Org/Wht
302 0.5 Org/Wht H4, S2
400 1.0 Yel/Red S2, solder connection
(410 Yel/Red, 415 Yel/
Red, 420 Yel)
401 0.8 Yel S2, K1
402 0.8 Yel X10, H4
403 0.8 Yel H4, H5
410 1.0 Yel/Red Solder connection

(400 Yel/Red), X10
415 1.0 Yel/Red Solder connection
(400 Yel/Red), X8

W2 Electrical Schematic with Auxiliary Alternator - 6X4 Gas
W2 Electrical Schematic with Auxiliary Alternator - 6X4 Gas (1 of 2)
210 Red/Blk or Blu/Blk

401 Yel
710 Pur/Blk
W13 Engine Wiring
Harness
F1 425 Yel
F2 200 Red 400 Yel/Red
215 Red 600 Brn
S1 Neutral 435 Yel
Fusible Start Switch Start W8 Engine R1 Carburetor
Links Wiring Harness Heater
Run X1 Blk
F3 Yel/Wht
Neutral Off
X2
Yel/Wht Yel/Wht Blk
K1 In
Gear S2 Key E1
Start
Relay Switch Spark
30 85 Plug
302 110 Blk X12 T1 Ignition T2
87a 87 86 Org/Wht Ignition
Coil
115 425 600 W9 Engine Blk/ Coil
Org
211 705 Blk Yel Brn Wiring HarnessYel Wht
Pur E2
Red 201 W10 Engine
Red 216 Spark
706 X13 Wiring X3 X3 X3
Red Pur
Harness Plug
700 Blk
Pur X13 X13
200 Red U
A1 Ignition Module
V1 Diode
N1 Voltage X13
Regulator/
Rectifier X4 X4 X4 X4
590 595
G1 X1 Brn/Yel Brn/Wht Yel Pnk
Battery Grn/ Wht/
W29 Alternator Wht Blu
Red Wiring Harness
Red B1
202 Red
X12 Left Pulser
100
B S Coil W11
590 595 Blk B2
Brn/Yel Brn/Wht Right Engine
205 Pulser Harness
Red
X1 Coil
X1
M1 W12 Engine
X12 M
Blk Blk
Starting Wiring Harness
Blk (Not Used) Motor G
G2
202 Red 200 Red Stator
302 Org/Wht
201 Red
102 Blk 101 Blk
+ G3 High 115 Blk
Capacity
G Alternator 110 Blk
(optional)
130 Blk X12 100 Blk
(Not Used)
W1 Shielded Battery Cables W2 Main Wiring Harness

Ground
SE1 - Starting SE2 - Charging SE3 - Ignition

W2 Electrical Schematic with Auxiliary Alternator - 6X4 Gas (2 of 2)
210 Red/Blk or Blu/Blk X8 X8 670 Yel/Wht
675 Yel/Blk
415
S5 Cargo Box Lift
Yel/Red Kit Switch (Opt.)
425 Yel
X10
600 Brn 402 Yel 400
435 Yel Yel/
420 Red
Yel On Off
430 Yel S6
423 Yel Light
Off On Switch
On Off
456 Yel/Wht
X5
Blu S4 E3 Right E4
S3 Park
Brake Differential Headlight Left
M M3 Switch Lock Switch
Radiator
110 Blk
Fan Motor
600 630 640
Brn Grn/Blk Grn
W4 Standard Headlight 100
Blu Wiring Harness Blk
H1 W18 or W19 Headlight
H2 H3 Wiring Harness (Opt.)
Discharge Park Brake Differential X11
M M2 Light Light Lock Light H5 Engine Oil
Fuel X6 Pressure Light
Pump + _
403 Yel
Blk
100 105
Blk Blk 125 Blk 120 Blk
H4 Engine
Coolant 302 Org/Wht 620
Temperature Tan
300
Light Org/Wht
X1 V2 X1
t0 B3 Radiator Core 115
Blk Diode
Temperature Switch
W1 Yel Blu/Red
Blk
t° t°
X7
135
Blk B4 Engine Coolant B5
W1 Temperature Switch Engine Oil
302 Org/Wht Pressure
Switch
115 Blk
105 Blk
110 Blk
SE4 - Fuel Pump and Fan SE5 - Instrumentation SE6 - Lights

W29 Auxiliary Alternator Wiring Harness - 6X4 Gas
W29 Auxiliary Alternator Wiring Harness - 6X4 Gas (1 of 2)
X13 To N1 Voltage X12 To W2 Main K1 Start Relay

Regulator/Rectifier Wiring Harness 705
595 700
100 425 W29 Alternator
200 Wiring Harness 600 425
401
215
595 X12 To W29
590
590 600 100 Alternator Wiring
200 Harness
590 130
101 600 425
X1 To W8 Engine 705
201 Wiring Harness V1 Diode
Negative 590 595 205
595 M2
Battery Cable
Fuel Pump
102
G3 Auxiliary W1 Shielded
Alternator Ground
202
Positive
135
Battery Cable
130 430 706
216 215 100
F3
205
211 210
M1 F2
201 200
Starting F1
Motor
Bolt
X9 To W17 Cargo Box

Lift Kit Wiring Harness
S1 Neutral Start
Switch
S3 Park
Brake Switch

W29 Auxiliary Alternator Wiring Harness - 6X4 Gas (2 of 2)
H1 Discharge
Light
125
X8 To S5 Cargo Box
Lift Kit Switch (Opt.) H5 Engine Oil
Pressure Light
403
301 H4 Engine Coolant
V2 Temperature
302
Light
403
H2 Park
Brake Light
H3 Differential
Lock Light
S2
Key Switch
W2 Main
Wiring Harness 415
425
410
420
400
X10
M3 Radiator
Fan Motor
X11
B3 Radiator
Core Temperature
S4 Differential Switch
Lock Switch
W29 Wiring Harness Wire Color Code Table - 6X4 Gas
Circuit Wire Color Termination Points Circuit Wire Color Termination Points
Number Size Number Size
100 3.0 Blk X13, N1 202 5.0 Red Solder Splice to 200/
201 Blk, Battery Pos
101 3.0 Blk G3 Gnd
425 1.0 Yel W2, X12, X 13
102 5.0 Blk Solder Splice to 100/
101 Blk, Battery Neg 590 3.0 Brn/Wht W2, X12, X13
200 3.0 Red Solder Splice, X13 595 3.0 Brn/Yel W2, X12, X13
201 3.0 Red Solder Splice, G3 600 1.0 Blu W2, X12, X13

W4 Standard Headlight Wiring Harness - 6X4 Gas
455 110 Blk

Yel
E32 Right
Headlight
S6
100 Blk E4 Left Headlight Switch
Headlight
400 Yel
456 Yel 455 Yel

456 Yel
X10 to W2 Main X11 to W4 Main

Wiring Harness Wiring Harness
400 Yel 100 Blk

110 Blk
MIF
W8 Engine Wiring Harness
To B4 Engine Coolant
Temperature Switch
To B5 Engine Oil
Pressure Switch From G2 Stator
Yel (W12 Engine Wiring Harness)
Blu/Red
To R1 Carburetor
Heater Yel
X1 From W2 Main
Blk Wiring Harness
Blk
Blk
X2 To W9
Engine Harness Yel/Wht
Yel/Wht
Blk
Blu/Red
M72546

To T1 and T2 Ignition Coils
Blk/Yel Yel/
Wht Wht
Yel/Wht
Yel/Wht
To X2 Connector on W8
Yel/Wht Engine Wiring Harness
Blk/Yel
Wht
To X2 Connector on W8
Blk/Wht Yel/Wht Engine Wiring Harness
Ground
Yel/Wht
Blk/Wht X3
To W10 Engine
Blk/Yel Wiring Harness
Wht
M72547
X3
From W9 Engine
A1 Ignition Module Wiring Harness
Yel Grn/Wht
Wht/Blu
Pink
Blk
Blk/Yel
Wht
Org/Wht
X4 or Org
To W11 Engine
Wiring Harness
M72548

Wht/Blu
Pnk Wht/Blu
Pnk
Yel
Grn/Wht
X4
From W10 Engine
Wiring Harness
B1 Left
Pulser Coil
B2 Grn/Wht
Right
Pulser Yel
Coil
M72549
To X1 Connector
G2 Stator
MIF
R1 Carburetor Heater
To X2 Connector
on W8 Engine
Wiring Harness
Carburetor Heater Ground Wire

MIF

ELECTRICAL OPERATION AND DIAGNOSTICS - 6X4 GAS
Operation and Diagnostics - 6X4 Gas System: Electrical
Yes - See “Indicator Lights Circuit Diagnosis - 6X4
Troubleshooting - 6X4 Gas Gas” on page 307.
System: Electrical (12) Are there light and horn problems?
(1) Does starter have cranking problems? Yes - See “Road Homologated Light and Horn Circuit
Diagnosis” on page 483 or “Light and Horn Circuit
Yes - See “Power Circuit Diagnosis - 6X4 Gas” on
Diagnosis (Earlier Model)” on page 437 or “Light and
page 292.
Horn Circuit Diagnosis (Later Model)” on page 458.
Yes - See “Cranking Circuit Diagnosis - 6X4 Gas” on
(13) Are there domestic headlight problems?
page 296.
Yes - See “Standard Headlight Circuit Diagnosis -
Yes - See “Ground Circuit Tests” on page 387.
6X4 Gas” on page 312.
Yes - See “Battery Test” on page 363.
(14) Are there cargo box lift problems?
(2) Does engine crank but not start?
Yes - See “Cargo Box Lift System Troubleshooting
Yes - See “Ground Circuit Tests” on page 387. Chart” on page 395 and “Cargo Box Lift Circuit
Diagnosis” on page 396.
Yes - See “Ignition Circuit Diagnosis - 6X4 Gas” on
page 299.
(3) Is there spark from the ignition?
page 299.
(4) Is the fuel pump operating?
page 299.
(5) Does the engine not shut off?
Yes - Check for a shorted circuit.
(6) Is an improper component working with a
switch?
Yes - Check for a shorted circuit.
(7) Is there a problem with the engine oil light?
Gas” on page 307.
(8) Does the battery go dead, discharge, or over
charge?
Yes - See “Charging Circuit Diagnosis - 6X4 Gas” on
page 303.
(9) Is there a discharge light problem?
Yes - See “Charging Circuit Diagnosis - 6X4 Gas” on
page 303.
(10) Are there cooling fan problems?
Gas” on page 307.
(11) Are there instrumentation light problems?
Electrical Operation and Diagnostics - 6X4 Gas - 289

Power Circuit Operation - 6X4 Gas Switched Power:
Voltage must be present at the following components with
Function: the key switch “ON or RUN” position:
Provides unswitched power to the primary components
• “A “and “S1” Terminals of key switch
whenever the battery is connected.
• Start Relay
Operating Conditions, Unswitched Circuits: • Voltage Regulator/Rectifier
Voltage must be present at the following components with
• Ignition Module
the key switch “OFF”:
• Fuel Pump
• Battery Positive Terminal
• Park Brake Switch
• “B” Terminal of Starting Motor
• Differential Lock Switch
• “B” Terminal of Key Switch
• Light Switch (Standard or Homologated)
• Voltage Regulator/Rectifier
• Lift Switch Connector
• Alternator Positive Terminal (if equipped)
• Engine Coolant Temperature Light
• Radiator Fan Motor
• Engine Oil Pressure Light
The positive battery cable connects the battery to the
starting motor. The starting motor bolt is used as a tie point These circuits are controlled by the key switch and are
for the rest of the electrical system. In systems with an protected by the fusible link.
alternator an additional positive battery cable connects to
the alternator bolt. Optional Lighting Kit and Lift Kit Power Circuits:
The battery cables, starting motor tie point and alternator See the appropriate schematics and diagnostic procedure
connections must be good for the machine’s electrical for these kits.
system to work properly. When optional kits are installed, the positive wires for these
The ground cable connections are equally important. kits are also connected to the starting motor. These leads
Proper starting motor and alternator operation depends on also contain fusible links to protect the wiring harnesses.
these cables and connections to carry the high current for
its operation.
The connection between the starting motor and key switch
is fused by a fusible link. This is a short piece of wire that is
designed to fail if current load is too high or a short occurs.
It protects the wiring harness from damage.
The charge wires running between the voltage regulator/
rectifier and starting motor and between the alternator and
the battery positive terminal are unprotected.

Power Circuit Schematic - 6X4 Gas
210 Blu/Blk
210
Blu/Blk S2 Key X8 To S5 Cargo
Switch Box Lift Switch
425 Yel 415 Yel/Red

X10
200 Red 400 Yel/Red
402
401 420
Yel
Yel Yel
Start
400
Run 423 Yel Yel/ 210
Off Red Blu/Blk
On Off
Off On
X5
Blu
S4 Differential S5
Lock Switch Light M
Switch
F2 Fusible S3 M3
Links Park Radiator
Brake 430 Yel Fan Motor
F1 Switch
On Off
215 Red
H4 Engine
F3 Coolant
401 Temperature
Yel
Light
30 85
435
M
87a 87
M2 Yel
86 Fuel
K1 Start Relay Pump X1
Yel/Wht H5 Engine Oil

Pressure
Light
E1 X2 E2
B S Yel/Wht Yel/Wht
Spark Spark
Plug Plug
M1
Starting
Motor N1 Voltage
425
M Regulator/ Yel
Rectifier
U T1 Ignition T2 Ignition
Coil Blk/ Coil
Yel Org Wht
X3 X3 X3
A1 Ignition Module
G1
Battery +
G3 Optional
G Alternator X4 X4 X4 X4
Yel Pnk
Grn/ Wht/
Wht Blu
B1 Left B2 Right
Pulser Coil Pulser Coil
W1 Shielded
Ground Unswitched Power Ground Switched Power

Power Circuit Diagnosis - 6X4 Gas
Test Conditions:
• Key switch in OFF position
Test/Check Point Normal If Not Normal

1. Starting motor battery Battery voltage Check battery cables and test battery. See “Battery Test” on
terminal page 363.
2. Start relay Battery voltage Check 215 Red wire. Replace F3 fusible link.
3. Radiator fan motor Battery voltage Check 210 Blu/Blk wire and connections. Replace F2 fusible
link.
4. Voltage regulator/rectifier Battery voltage Check 205 Red wire and connections.
5. Alternator, high capacity Battery voltage Check 202 and 201 Red in W29 Harness
(optional)
6. Key switch Battery voltage Check 200 Red wire and connections. Replace F1 fusible link.
Test Conditions:
• Key switch in RUN position

7. Key switch Battery voltage Replace S2 key switch.
8. Voltage regulator/rectifier Battery voltage Check 425 Yel wire and connections.
9. Light switch Battery voltage Check 400 Yel/Red wire and connections.
10. Lift switch connector Battery voltage Check 415 Yel/ Red wire connection.

1
F1 Fuse-Link
F2 Fuse-Link
F3 Fuse-Link
2
215 Red
K1 Start Relay
M1 Starting Motor
M3 Radiator Fan Motor
202 Red
G1 Battery
210 Blu/Blk 3
G3 Alternator
(Optional)
5 201 Red
S5 Cargo Box
Lift Switch (Opt.)
10 8
415 Yel/Red 425 Yel
4
205 Red
S6 Light Switch S2 Key Switch

N1 Voltage Regulator/Rectifier
9 200 Red
400 Yel/Red 7
400 Yel/Red
401 Yel

Power Circuit Diagnosis - 6X4 Gas (continued)
Test Conditions:
• Key switch in ON position

11. Differential lock switch Battery voltage Check connection of 420 Yel wire.
12. Park brake switch Battery voltage Check 423 Yel wire and connections.
13. Fuel pump motor Battery voltage Check 430 Yel wire and connections.
14. Ignition module Battery voltage Check 435 Yel wire and connections.
15. Ignition coils Battery voltage Check X3 engine harness connector and Yel/Wht wire at
ignition module.
S4 Differential Lock Switch S3 Park Brake Switch
11
12
420 Yel
423 Yel
423 Yel
430 Yel
Yel/Wht
13
15 430 Yel
T1, T2 Ignition Coils
A1 Ignition Module
M2 Fuel Pump
14
435 Yel

Cranking Circuit Operation - 6X4 Gas Theory of Operation:
Current from the power circuit (200 Red) flow through a
Function: fusible link to the key switch.
To energize the starting motor solenoid and engage the
The S2 key switch allows current to flow to the start relay
starter motor to crank the engine.
when in the run or start position (401 Yel). With the
Operating Conditions: transmission in neutral the S2 key switch connects the
neutral start circuit (706 Pur, V1 Diode, 705 Pur and 710
• Key switch in START position Pur) to ground, allowing the start relay to activate.
• Transmission in NEUTRAL The start relay then allows a higher current to pass from the
battery, through the F2 fusible link and start relay to
energize the starter solenoid (215 Red, 700 Pur).
With the starting motor solenoid activated, high current
from the battery passes through the battery cable, across
the solenoid and energizes the starting motor.
Cranking Circuit Schematic - 6X4 Gas
401 Yel
200 Red
215 Red 400
Yel/
710 Red
F1 F3 Start Pur/
Blk
Run
Fusible
Off
Links 30 85
K1 Start
Relay
87a 87 86 S2 Key 423
Switch Yel
706 Pur 705 Pur

700 Pur
V1 Diode
X1 Neutral 430
B S Yel
In Gear
S1
Neutral Start M2
Switch M Fuel
M1
Starting Pump
M Motor
G1 Battery
100 Blk 105 Blk
100 Blk
110 Blk
W1 Shielded
Ground X11 To W4 Standard
Headlight Wiring Harness
Unswitched Power Switched Power Neutral Start Circuit Ground

Cranking Circuit Diagnosis - 6X4 Gas
Test Conditions:
• Transmission in NEUTRAL and brake set

1. Key switch Battery voltage Check 200 Red wire and F3 fusible link. See “Power Circuit
Diagnosis - 6X4 Gas” on page 292.
2. Start relay Battery voltage Check 215 red wire and connections. Replace F2 fusible link.
Test Conditions:
• Key switch in START position

3. Key switch Battery voltage Replace S2 key switch.
4. Start relay Battery voltage Test 401 Yel wire and connections.
Test Conditions:
• Remove connector from start relay
• Change meter to ohm scale
• Test for continuity to ground with transmission in neutral and key switch in START position

5. Relay connector to neutral Continuity in one Continuity in both directions replace V1 diode or wiring harness.
start switch direction only No continuity in either direction, repair wire.
6. Neutral start switch Continuity across Check transmission linkage neutral adjustment. Replace
(Switch disconnected) neutral start switch neutral start switch.
7. Neutral start switch to key Continuity Repair 710 Pur/Blk wire.
switch
8. Key switch Continuity across Replace S2 key switch.
switch in START
position
8. Key switch to engine ground Continuity Check Blk wires and connection at fuel pump, light harness
connector, and engine and battery ground location. Repair
wires and/or connections.
10. Starting motor solenoid “S” Battery voltage No voltage: Test 700 Pur wire and connections. Replace K1
terminal start relay.
Voltage: Check battery ground cable and connections. Test or
replace starting motor solenoid.

S2 Key Switch
4
1
401 Yel
200 Red
215 Red
7
2
710 Pur/Blk
705 Pur
8 3
400 Yel/Red V1 Diode 5
110 Blk 401 Yel K1 Start Relay
S1 Neutral Start Switch
F1 Fusible Link
200 Red
215 Red
F3 Fusible Link
710 Pur/Blk
700 Pur 6
706 Pur
10
5
M1 Starting Motor
Engine Ground
100 Blk
W1 Shielded Ground
G1 Battery

Ignition Circuit Operation - 6X4 Gas pump are all powered by this circuit.
Two pulser coils, one for each cylinder, are mounted in a
Function: fixed position next to the flywheel. As the flywheel turns, a
To create a spark at the correct time, that ignites the fuel tab on the flywheel travels past the pulser coils and
and air mixture. produces current in the pulser coils by electromagnetic
induction. Pulser coil current flows to the ignition module as
Operating Conditions: a signal for the module to ground the coil primary windings.
• Key switch must be in the START or RUN position. When the current flow stops in the primary windings, the
magnetic field collapses and induces high voltage in the
Theory of Operation: secondary coil windings. The high voltage current travels
through the plug wire and jumps the gap at the spark plug,
The ignition system is a transistor controlled, battery
igniting the fuel/air mixture.
ignition design. The battery supplies current to the ignition
coils. The timing is controlled by the ignition module and is Each spark plug fires on both the compression and exhaust
not adjustable. The engine is shutoff by de-energizing the stroke. The spark produced during the exhaust stroke does
ignition coils. not affect engine operation because there is no
compression or combustible mixture in the cylinder.
Current flows from the key switch to the left and right
ignition coils. The differential lock, park brake and fuel
Ignition Circuit Schematic - 6X4 Gas
X8 To S5 Cargo Box
Lift Kit Switch (Optional)
200 Red 400 Yel/Red 410 Yel/Red
X10 To
W4 Standard
Start
435 Yel 430 Yel Headlight
Run Wiring Harness
Off 423 Yel
Off On
On Off
X1 To W8 Engine
S2 Key Wiring Harness
Switch
S4
X2 T2 Ignition Coil S3 Differential
T1 Ignition Coil Park Lock Switch
Yel/Wht Yel/Wht Brake
Switch
E1 Blk/ E2
Spark Yel Spark
Plug Org Plug
Wht
Blk X3 X3 X3 M M2
Fuel Pump
A1 Ignition Module
Engine
Ground X4 X4 X4 X4
Grn/ Yel Pnk Wht/
Wht Blu
B1 Left B2 Right
Pulser Coil Pulser Coil

Ignition Circuit Diagnosis - 6X4 Gas
Test Conditions:

1. Main wiring harness to Battery voltage Check connections at differential lock and park brake switches
engine wiring harness and at the fuel pump. See “Power Circuit Diagnosis - 6X4 Gas”
connector on page 292.
2. Positive terminals of right Battery voltage Check Yel/Wht wire of coil harnesses and X2 connections at
and left ignition coils engine harness connector.
3. Ignition module connector Battery voltage Check Org wire and connections through module and engine
module side. (Org or Org/Wht harness power connector.
wire lead)
4. Right and left negative Battery voltage minus No voltage: Replace ignition coil.
terminal of ignition coils. (Wht voltage drop across
and Blk/Yel leads) coils
Test Conditions:
• Key switch to OFF position

5. Ignition module connector Maximum 0.1 ohms Check ignition module ground connection.
(Blk ground wire) resistance
Test Conditions:
• Meter set to AC voltage
• Plug wires grounded
• Key switch to START position
• Engine cranking

6. Spark plugs Spark plug tester: Hot Inspect or replace spark plug(s).
blue spark
7. Pulser coil connection (Wht/ 0.1 - 1.0 VAC Check pulser coil connections. Test pulser coil resistance.
Blu and Pnk, then Grn/Wht
Coil resistance 85 - Replace pulser coil.
and Yel)
270 ohms
8. Ignition module connector Using test light: Rapid Flashing light: Check coil resistance.
(Wht then Blk/Yel wire leads) flashing light, not No Light: Check connections. Replace ignition module.
steady glow.
Coil resistance:
Primary windings 3.4 -
4.6 ohms.
Secondary windings
10.4 - 15.5 ohms

3
7
5
7
Org/Wht Blk
Yel Pink
Pnk or Org
Wht Blk/Yel
Grn/Wht Wht/Blu
Back-Side of
Ignition Module
8 A1 Ignition Module
Connectors
Wht/
B1, B2 Pulser Blu
Coils Grn/Wht Pnk
Yel
X4 W10 Engine Wiring Harness

6 Blk To W11 Engine Wiring Harness
2 T1, T2 Ignition Coils
Yel/Wht X3 W9 Engine Wiring Harness
To W10 Engine Wiring Harness
Blk/
Yel
Wht
E1, E2 Spark Plug

4
Org
1
X2 W8 Engine Wiring Harness

Org To W9 Engine Wiring Harness
X1 W2 Main Wiring Harness To

M56701

Charging Circuit Operation - Stator Charging Circuit Operation - Auxiliary
Alternator (Optional)
Function:
To maintain battery voltage between 12.4 and 13.2 volts. Function:
To maintain battery voltage between 12.4 and 13.2 volts.
Operating Conditions:
The key switch must be in the RUN position with the engine Operating Conditions:
running for the charging system to operate. The key switch must be in the RUN position with the engine
running for the charging system to operate.
System Operation (Stator equipped):
The charging system is a permanent magnet and stator System Operation:
design. Charging output is controlled by a voltage The charging system consists of the G3 alternator with an
regulator/rectifier. integrated voltage regulator/rectifier. Charging output is
With the key switch in the run position, battery sensing controlled by a regulator/rectifier.
circuit current flows from battery positive terminal to With the key switch in the RUN position, battery sensing
starting motor terminal, fusible link, key switch, and circuit current flows from battery positive terminal 202 and
regulator-rectifier. The battery sensing circuit allows the 201 Red wires to the auxiliary alternator internal voltage
voltage regulator/rectifier to monitor battery voltage. regulator/rectifier. The battery sensing circuit allows the
As the flywheel turns, a permanent magnet located in the voltage regulator/rectifier to monitor battery voltage.
flywheel induces AC current in the stator. The AC current A rotating permanent magnet in the alternator induces AC
flows to the voltage regulator/rectifier. The voltage current in the alternator stator coils. The AC current flows to
regulator/rectifier converts AC current to DC current the voltage regulator/rectifier. The voltage regulator/rectifier
needed to charge the battery. converts AC current to DC current needed to charge the
If battery voltage is low, the voltage regulator/rectifier battery.
allows DC current to flow to the battery to charge it through If battery voltage is low, the regulator/rectifier allows DC
the battery charging circuit (205 Red). When the battery is current to flow to the battery to charge it through the battery
fully charged, the voltage regulator stops current flow to the charging circuit (201 and 202 Red). When the battery is
battery. fully charged, the voltage regulator/rectifier stops current
If the stator output current falls below the system usage or flow to the battery.
is insufficient to maintain a preset voltage, the voltage The ground circuit (101 and 102 Blk) provides a path to
regulator provides current to turn on the discharge indicator ground for the voltage regulator/rectifier.
light.
The ground circuit provides a path to ground for the voltage
regulator/rectifier

Charging Circuit Schematic - Stator
S2 Key
200 Red Switch 400 Yel/Red
Run
F1 Fusible Off Start
600 Brn
G1 Battery Link Run 425
Off Yel H1 H2 H3
Discharge Park Brake Differential
Light Light Lock Light
+ _
205 Red U
N1 Voltage 590 595
Regulator/ 125 Blk 120 Blk
Brn/Yel Brn/Wht
Rectifier
X1 X1
M1 Blk Blk
Starting
M Motor G
G2
Stator
115 Blk
100/115/130 Blk 130 Blk
Charging Circuit Schematic - Auxiliary Alternator
S2 Key H1 H2 H3
200 Red Switch 400 Yel/Red Discharge Park Brake Differential
425 Light Light Lock Light
Yel
+ _
Run X12
F1 Fusible Off Start
G1 Battery Link Run 425 600
Yel Brn 125 Blk 120 Blk
Off
X13 N1 Voltage
600 Brn
Regulator/
M1 Rectifier
Starting
Motor X13 X13
U
590 595
Brn/Yel Brn/Wht
M
X13
205 Red 590 595
X12 Brn/Yel Brn/Wht W29 Alternator
(Not Used) Wiring Harness
202 Red 200 Red
X12
590 595 115 Blk
201 Red Brn/Yel Brn/Wht
+ X1 X1
G3
Alternator Blk Blk
G
G
101 Blk
102 Blk 100 Blk
100/115 Blk
130 Blk
(Not Used)

Charging Circuit Diagnosis - 6X4 Gas
Test Conditions:
• Transmission in NEUTRAL
• Engine OFF

1. Voltage regulator/rectifier Battery voltage Check 425 Yel wire and connections. Check F1 fusible link and
S2 key switch. See “Power Circuit Diagnosis - 6X4 Gas” on
page 292.
2. High Capacity Alternator (If Battery voltage Check 202 and 201 Red wires and connections.
equipped)
3. Voltage regulator/rectifier Greater than 0 volts - Greater than 0.2 volts: Test voltage regulator/rectifier ground
less than 0.2 volts circuit.
4. Charge indicator light Battery voltage Check 600 Brn wire and connections X12, X13.
(600 Brn Wire)
5. Charge indicator light Greater than 0 volts - 0 volts: Replace bulb.
less than 0.2 volts Greater than 0.2 volts: Check all connections and ground wires
for open or poor connections.
Test Conditions:
• Stator disconnected
• Engine running at high idle

6. High capacity alternator Minimum unregulated Check stator leads and connector. Check flywheel magnets.
voltage output - 45 Replace stator.
amps at 12.2-13.8 V
7. Voltage regulator/rectifier Minimum 20 Amps at Replace voltage regulator/rectifier. See “Alternator Output -
(Machine SN -007496) 12.2 -13.8 V 4X2” on page 383.
(Engine SN -038265)
8. Voltage regulator/rectifier Minimum 16 Amps at See “Stator - Regulated Amperage and Voltage Tests” on
(Machine SN 007497-) 12.2 -13.8 V page 366. Replace voltage regulator/rectifier.
(Engine SN 038266 -)
9. Battery Voltage above normal Check for excessive load on electrical system.
battery voltage

205 Red
200 Red
F1 Fusible Link
3
3
130 Blk
130 Blk
425 Yel
M1 Starting Motor
425 Yel
1
1
205 Red 8 N1 Voltage
(200 Red) Regulator/Rectifier
205 Red 7 N1 Voltage
Regulator/Rectifier
H1 Discharge Light
130 Blk
G1 Battery
W1 Shielded Ground 5
125 Blk
202 Red 600 Brn

4
200 Red
G2 Stator
201 Red
Blk
Blk
G3 High Capacity
Alternator (optional) X1 W2 Main Wiring Harness
590 Brn/Yel
To W12 Engine Wiring Harness
2 6
595 Brn/Wht

Indicator Lights Circuit Operation - 6X4 Gas
Function:
Engine Oil Pressure Light:
To alert operator of low engine oil pressure by illuminating a
warning light.
Engine Coolant Temperature Light:
Inform operator of critical engine and coolant operating
temperature by illuminating a warning light.
Park Brake Light:
Informs the operator that the park brake is ON by
illuminating a warning light.
Differential Lock Light:
Inform the operator that the differential Lock is ON by
illuminating a warning light.
Operating Condition:
The key switch must be in RUN position.
Theory of Operation:
Oil Pressure Light:
With the engine OFF and key in RUN position, oil pressure
will be below 28 kPa (4 psi). The oil pressure switch will be
closed, completing the circuit path to ground and
illuminating the light. This will inform the operator that the
light is functioning.
When the engine is started and running, the light should go
out when the oil pressure is adequate to open the pressure
switch, turning out the light.
Engine Coolant Temperature Light:
When the key switch is in the START position, the ground
circuit is allowed to pass through the V2 diode and the key
switch starting circuit to ground. This will momentarily turn
on the light as a bulb check, When the engine starts and
the key switch is returned to the RUN position, the light will
go out. If the engine temperature reaches 109° C ± 1° C
(228° F ± 2° F), the sensor will close, providing a path to
ground through the engine block.
Park Brake Light:
When the park brake is set the switch is released (closes),
allowing current to flow to the warning light. When the
brake is released the switch is opened and the light goes
out.
Differential Lock Light:
When the differential lock lever is moved to engage the
differential lock, the switch is depressed (closed), allowing
current flow to the light. When the differential is released,
the switch is released (open), and the light goes out.

Indicator Lights Circuit Schematic - 6X4 Gas
302
Org/Wht

402 Yel
X10 To W4
Standard
Start Headlight
Run Wiring
Harness
Off
S2 Key
110 Switch
Blk
115
Blk
F1 S4
430 Yel
Differential
B S 423 Yel Lock Switch
Off On
On Off
S3
Park H4 Coolant H5 Engine
M Brake Temperature Oil Pressure
Switch Light 403 Yel Light
M1 Starting
630 640
Motor Grn/Blk Grn
H2
Park Brake 310 Org/Wht
Light
300
120 Blk H3 Org/Wht 620 Tan
Differential
+ M2 Lock Light
Fuel X1 X1
Pump V2
Diode
G1 Battery
t0 t0
115 Blk
B4 Engine Coolant B5
Engine Oil
Temperature Switch Pressure Switch
302 Org/Wht
100 Blk
105 Blk X11 To W4

110 Blk Standard Headlight
Wiring Harness
W1 Shielded
Ground

Indicator Lights Circuit Diagnosis - 6X4 Gas
Test Conditions:
• Engine OFF
• Differential lock engaged
• Park brake set

1. Engine oil pressure light Battery voltage Check 402 and 403 Yel Wires and connections. See “Power
Circuit Diagnosis - 6X4 Gas” on page 292.
2. Engine oil pressure light Battery voltage Replace light bulb.
3. Engine oil pressure switch Battery voltage Check 620 Tan wire and connections.
4. Engine oil pressure switch Continuity to ground Check engine ground. If OK replace engine oil pressure switch.
(Wire lead disconnected)
5. Engine coolant temperature Battery voltage Check 402 Yel wire. See “Power Circuit Diagnosis - 6X4 Gas”
light on page 292.
6. Engine coolant temperature Battery voltage Replace light bulb.
light
7. Engine coolant temperature Battery voltage Check 300 Org/Wht wire and connections.
switch
8. Engine coolant temperature Switch closes at 108° Replace Switch. See “Engine Coolant Temperature Switch Test
switch - 110° C (226° - 230° - 6X4’s” on page 381.
F). Switch opens at
101° - 107° C (214° -
225° F).
Test Conditions:
• Meter positive lead to voltage source
• Negative lead to ground side of coolant light

9. Engine coolant temperature Battery voltage Test V2 diode and check 302 Org/Wht wire lead and
light connections to S2 key switch.
(Momentarily turn key switch
to start. This tests ground
circuit and diode for bulb test
circuit)
10. Key switch Continuity to ground. Check ground wire 110, 105, 100 Blk wires and connections.
Maximum 0.1 ohm
resistance,
11. Key switch Battery voltage Test or replace key switch. Test V2 diode.

620 Tan
2 3
620 Tan
4
1 403 Yel
H5 Oil Pressure Light
B5 Engine Oil Pressure Switch
S2 Key Switch
11
302 Org/Wht
6
10
110 Blk 9
115 Blk 310 Org/Wht
1 5 V2 Diode
11
402 Yel 300 Org/Wht
403 Yel
H4 Engine Coolant Temperature Light
300 Org/Wht
B4 Engine Coolant Temperature Switch

Fuel Pump and Fan Motor Operation - 6X4 connected directly to the battery and does not depend
Gas upon the start switch position.
Radiator Fan Motor: Theory of Operation:
Operates whenever the coolant switch is closed. Operates when the radiator core temperature switch closes
when coolant heats the outer radiator core to 71° ± 4° C
The radiator core temperature switch closes when the (160° ± 7° F). The radiator core temperature switch
coolant heats to 89° C (192° ± 7° F) raising the outer monitors outer radiator core temperature, not engine
radiator core temperature to 71° C (160° ± 7° F). coolant temperature.
NOTE: The outer radiator core temperature is Fan motor may run after engine is shutoff. Fan motor will
approximately 20° C (36° F) lower than engine coolant stop when outer radiator core temperature cools to 60° ± 4°
temperature. C (140° ± 7° F) and radiator core temperature switch
opens.
The fan motor will stop when the coolant temperature drops
to 80° C (177° ± 7° F), the outer radiator core temperature Fuel Pump:
cools to 60° ± 4° C (140° ± 7° F), and the radiator core
temperature switch opens. The radiator fan motor circuit is Operates whenever the key is in the run or start position.
Fuel Pump and Fan Motor Schematic - 6X4 Gas
210 Blu/Blk
200 Red 400 Yel/Red
420
Start Yel
430 Yel
F1 Run
F3 Off 423 Yel

Fusible Off On
On Off
Links X5
S2 Key
Switch Blu
M3
M Radiator S4
Fan Motor S3
Park Differential
Blu Brake Lock Switch
G1 Battery Switch
X6
B Blk
M2 M
Fuel
Pump t0 B3
Radiator Core
M Temperature Switch
M1 100 Blk
Starting Blk
Motor X7
100/135 Blk 135 Blk
W1 Shielded
Ground

Fuel Pump and Fan Motor Diagnosis - 6X4 Gas
Test Conditions:

1. Fuel pump Battery voltage Check connector. See “Power Circuit Diagnosis - 6X4 Gas” on
page 292.
2. Fuel pump. Greater than 0 - less No voltage: Replace pump. Greater than 0.2 volts: Check
than 0.2 volts ground wire (100 Blk) and connections.
Test Conditions:

3. Radiator fan Battery voltage Check 210 Blu/Blk wire and connections. Replace F1
fusible link.
4. Fan to B3 radiator core Fan should run. Replace fan.
temperature switch connector. Fan amperage draw - 7 amps
Disconnect and jump fan lead
to good ground.
5. Radiator core temperature Coolant switch closes (fan Check Blk wire, X7, and 135 Blk wire. Replace switch.
switch starts) at 67° - 75° C (153° -
167° F). Coolant switch opens
at 56° - 64° C (133° - 147° F).
M3 Radiator Fan Motor
M2 Fuel Pump
2
1
430 Yel 100 Blk
435 Yel 105 Blk
210 Blu/Blk

Standard Headlight Circuit Operation - 6X4 Operating Conditions:
Gas The key switch must be in the RUN position.
NOTE: If the Light and Horn kit option is added, the Theory of Operation:
new harness plugs into the light harness connector
(X10) and connector (X11). The light switch and the The headlight harness is attached to the W2 main wiring
original light harness are removed. harness. Power from the headlight harness connector X10
is connected to the S6 light switch. Current then flows from
Function: the switch to the headlights.
Provides power to the headlights.
Standard Headlight Circuit Schematic - 6X4 Gas
X10 W2 To Main Wiring

Harness To W4 Standard
200 Red 400 Yel/Red 410 Yel/Red Headlight Wiring Harness
F1
Start
Fusible
G1 Battery Link Run
Off (0) (1)
S6
Light
Switch 0, 1
S2 Key
Switch
M2
Fuel
B S Pump
M 455
Yel/Wht 456
Yel/Wht
M1
M Starting
Motor E3 E4
100 105 Right Left
Blk Blk
Head- Head-
Light 110 100 Light
Blk Blk
100 Blk
W1 Shielded
Ground X11 W2 To Main Wiring
Harness To W4 Standard
Headlight Harness

Standard Headlight Circuit Diagnosis - 6X4 Gas
Test Conditions:
• Key switch must be in the RUN position
• Light switch ON

1. Light switch Battery voltage Check connection at X10 connector. See “Power Circuit
Diagnosis - 6X4 Gas” on page 292.
2. Light switch Battery voltage Replace light switch.
3. Left headlight Battery Voltage Check 455 Yel/Wht wire and connections.
4. Left headlight Greater than 0 volts - 0 volts: Replace headlight.
less than 0.2 volts Greater than 0.2 volts: Check ground circuit connection at light
harness ground connector X11 and 105 and 100 Blk wires and
connections.
5. Right headlight Battery voltage Check 456 Yel/Wht wire and connections.
6. Right headlight Greater than 0 volts - 0 volts: Replace headlight.
less than 0.2 volts Greater than 0.2 volts: Check ground circuit connection at light
harness ground connector X11and 105 and 100 Blk wires and
connections.
S6 Light Switch
400 Yel/Red E4 Left Headlight
455 Yel/Wht
3
455 Yel/Wht
2 456 Yel/Wht 4
110 Blk
E3 Right Headlight
456 Yel/Wht
5
6
100 Blk

Gas 6x4 Gator Electrical From TM1518

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Gas 6x4 Gator Electrical From TM1518

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ELECTRICAL COMPONENT LOCATION

Component Location - 6X4 Gas

M56334L F - S2 Key Switch

Electrical Component Location - 274

M56334R G - K1 and K2 Cargo Box Lift Directional Relays

Electrical Component Location - 275

F2 - Fusible Link (SE1, W2) X7 - B3 Radiator Core Temperature Switch to W1 Shielded

M2 - Fuel Pump (SE4, W2)

Electrical Schematics and Harnesses - 6X4 Gas - 276

210 Red/Blk or Blu/Blk

Battery Cables W2 Main Wiring Harness

Optional Lift Kit Component

SE1 - Starting SE2 - Charging SE3 - Ignition

Electrical Schematics and Harnesses - 6X4 Gas - 277

100 105 Blk 125 Blk 120 Blk

Battery Cables W2 Main Wiring Harness

SE4 - Fuel Pump and Fan SE5 - Instrumentation SE6 - Lights

Electrical Schematics and Harnesses - 6X4 Gas - 278

M1 216 215 100

Positive Battery Cable

Electrical Schematics and Harnesses - 6X4 Gas - 279

X10 To W4 Standard Headlight Wiring Harness;

X11 To W4 Standard Headlight Wiring Harness;

Electrical Schematics and Harnesses - 6X4 Gas - 280

105 1.0 Blk X11, M2 425 1.0 Yel Solder connection

205 2.0 Red M1, N1 700 2.0 Pur K1, X1

210 1.0 Red/Blk, F2, M3 705 0.8 Pur V1 Diode, S1

410 1.0 Yel/Red Solder connection

Electrical Schematics and Harnesses - 6X4 Gas - 281

210 Red/Blk or Blu/Blk

W1 Shielded Battery Cables W2 Main Wiring Harness

SE1 - Starting SE2 - Charging SE3 - Ignition

Electrical Schematics and Harnesses - 6X4 Gas - 282

210 Red/Blk or Blu/Blk X8 X8 670 Yel/Wht

Battery Cables W2 Main Wiring Harness

Optional Lift Kit Component

SE4 - Fuel Pump and Fan SE5 - Instrumentation SE6 - Lights

Electrical Schematics and Harnesses - 6X4 Gas - 283

X13 To N1 Voltage X12 To W2 Main K1 Start Relay

X9 To W17 Cargo Box

Electrical Schematics and Harnesses - 6X4 Gas - 284

W29 Wiring Harness Wire Color Code Table - 6X4 Gas

Electrical Schematics and Harnesses - 6X4 Gas - 285

455 110 Blk

456 Yel 455 Yel

X10 to W2 Main X11 to W4 Main

400 Yel 100 Blk

W8 Engine Wiring Harness

Electrical Schematics and Harnesses - 6X4 Gas - 286

To T1 and T2 Ignition Coils

W10 Engine Wiring Harness

Electrical Schematics and Harnesses - 6X4 Gas - 287

W12 Engine Wiring Harness

W13 Engine Wiring Harness

Carburetor Heater Ground Wire

Electrical Schematics and Harnesses - 6X4 Gas - 288

Electrical Operation and Diagnostics - 6X4 Gas - 289

Electrical Operation and Diagnostics - 6X4 Gas - 290

400 Yel/Red 410 Yel/Red

Yel/Wht H5 Engine Oil

Electrical Operation and Diagnostics - 6X4 Gas - 291

Test/Check Point Normal If Not Normal

Test/Check Point Normal If Not Normal

Electrical Operation and Diagnostics - 6X4 Gas - 292