Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) WIRING DIAGRAMS 0 HEADLIGHT (watt) TAILLIGHT (watt) ELECTRICAL SYSTEM OUTPUT (watt) Tundra R 60/55 hal. 8 /27 240 Skandic LT 60/55 hal. 8 /27 240 Skandic WT/SWT 60/55 hal. 8 /27 240 Skandic WT LC 60/55 hal. 8 /27 220 MODEL hal. = halogen WIRING DIAGRAM LEGEND WIRE COLORS AND CIRCUIT WARNING XX/XX Ensure all terminals are properly crimped on the wires and all connector housings are properly fastened. XX/XX 1- MC D A00I04F XX/XX A00I04E 1. 2. 3. 4. 1 Wire colors Housing area Housing number per area Wire connector location in housing MMR2002_038_11_01A.FM 1 - MC D 2 34 The first color of a wire is the main color, second color is the stripe. Example: YL/BK is a YELLOW wire with a BLACK stripe. COLOR CODE BE – BK – BL or BU – BR – GN – GY – BEIGE BLACK BLUE BROWN GREEN GREY OR RD VI WH YL – – – – – ORANGE RED VIOLET WHITE YELLOW 11-01-1 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Following table shows wire colors related to electrical circuits. WIRE COLOR ELECTRICAL CIRCUIT ADDITIONAL INFORMATION BLACK/YELLOW ENGINE SHUT OFF – key switch – tether cord switch – emergency switch BLACK (small) Ground for shut off, RER pilot lamp, beeper and beeper switch BLACK (big) Ground for starter (–) BEIGE RER switch Must be grounded to activate RER. BEIGE/BLACK Reverse alarm and pilot lamp Current returns by BLACK wire. YELLOW YELLOW/BLACK YELLOW/GREEN (Skandic series) 12 volts (AC) If shorted, magneto stops producing electricity. RED 12 volts (DC) (+) For starter motor RED/GREEN 12 volts (DC) (+) For starter solenoid RED/BLUE 12 volts (DC) (+) Rectifier output GREY 12 volts (AC) High beam VIOLET/GREY 12 volts (AC) Low beam WHITE 12 volts (AC) Brake light Current returns by YELLOW/BLACK wire connected to taillight. WHITE/RED 12 volts (AC) Low oil level Current returns by YELLOW/BLACK wire connected to oil level sensor. BLUE 12 volts (AC) Fuel level indicator Current returns by YELLOW wire connected to fuel level sensor. ORANGE 12 volts (AC) Heated grips (max.) ORANGE/VIOLET 12 volts (AC) Heated grips (min.) BROWN 12 volts (AC) Heated throttle lever (max.) BROWN/YELLOW 12 volts (AC) Heated throttle lever (min.) GREEN 12 volts (AC) Temperature gauge VIOLET 12 volts (AC) Engine overheating light 11-01-2 Must be grounded to stop engine. Current returns by YELLOW/BLACK wire connected to headlamp. Current returns by YELLOW/BLACK wire connected to heating elements. Current returns by YELLOW wire connected to sensor. MMR2002_038_11_01A.FM Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) CONNECTOR HOUSING AREA XX/XX 1 - MC D 1 A00I04G 9 7 6 11 4 5 8 3 2 1 10 A06H33C AREA LOCATION 1 Front of engine compartment 2 Magneto 3 Carburetors 4 Near of intake silencer 5 Near driven pulley 6 Under console 7 Under hood 8 Near fuel tank 9 Rear of seat 10 Under engine 11 On injection oil reservoir CONNECTOR LOCATION IN HOUSING XX/XX A00I04H MMR2002_038_11_01A.FM 1- MC D D 11-01-3 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) DEUTSCH A A A A C A B B B B A D C B A A C B C A D B A B 1 2 C B C A A D C A C B C A D 1 2 B A B B F V01G0EU 11-01-4 D C A B B C A B ED 4 3 4 3 1 2 A 1 2 3 C D 3 21 B PACKARD A 3 A B B 2 1 C A B A 1 2 B B B C 85 87 87a 86 30 A A B A 1 A C C A B B B 2 C A CB B D 6 5 4 1 2 3 A 1 2 3 4 5 6 FE 6 5 4 A CB 12 11 10 9 8 7 12 11 10 9 8 7 1 2 3 4 5 6 MMR2002_038_11_01A.FM Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) SYMBOLS DESCRIPTION Beam and tail light Female terminal Male terminal Electronic module Meter Electric motor Low level sensor Buzzer Ignition coil Normally close switch Normally open switch Male terminal on instrument Engine ground Frame ground Spark plug Meter movement Frame Bulb Pilot Analog sensor Solenoid valve Magneto (Delta) 3 position switch Heating element Fuse Trigger coil Battery Diode Partially illustrated component A00E55S MMR2002_038_11_01A.FM 11-01-5 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) UNPLUGING CONNECTORS Always unplug connectors by pulling on housing not on wire. To remove: – Insert a screwdriver or Snap-on TT 600-5 from opposite side of wire and pry locking tab. – While holding locking tab pried, pull connector toward wire side. 2 1 A06E1PA A00E1EA TYPICAL TAB AND RECEPTACLE CONNECTOR REMOVAL Tab Connector It is locked in its housing by a spring tab on its side. Removal is done by squeezing this tab. Step 1 : Insert screwdriver here Step 2 : Pull this side Locking Receptacle Connector To remove: – Insert tool Snap-on TT 600-5 in access opening then pull housing toward wire side. 1 A00E1DA TAB CONNECTOR 1. Locking tab A06E1QA 11-01-6 MMR2002_038_11_01A.FM Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) Waterproof Connector Housing Female Connector Housing To remove: – Insert tool Snap-on TT 600-5 under lock and twist to lift it. 1 A01E34A 1. Lock – Pry tab to free connector then pull wire out of housing. A01E31A – Pry tab to free connector then pull wire out of housing. A01E35A MALE CONNECTOR HOUSING — CUT-AWAY TAB AND RECEPTACLE CONNECTOR INSTALLATION A01E32A FEMALE CONNECTOR HOUSING — CUT-AWAY Male Connector Housing To remove: – Using a small hook, pull out the lock. Prior to installing a connector, make sure locking tab is sufficiently lifted to properly lock. Insert tab and receptacle connectors in their respective housings as shown in following illustrations. Push sufficiently so that they snap. Try pulling wire to ensure they are properly locked. 1 A00E1GA 2 1. Tab 2. Housing A01E33A 1 1. Lock MMR2002_038_11_01A.FM 11-01-7 Section 11 WIRING DIAGRAMS Subsection 01 (WIRING DIAGRAMS) 1 2 A00E1FA TYPICAL 1. Receptacle 2. Housing ACCESSORIES INSTALLATION On all electric start models: The direct current (DC) utilizes the snowmobile frame as ground “wire” while all alternating current (AC) consumers (lights, heated grips, fuel gauge, etc.) utilize a separate ground wire. Never interconnect AC and DC grounds as an AC voltage drop will result. When installing accessories on any snowmobile, connect their wires directly to the YELLOW and YELLOW/BLACK lighting coil wires. Even if manual start models have an AC ground to the chassis (on voltage regulator), all accessories utilize a ground wire isolated from chassis. When an electric starter kit is installed, the voltage regulator and its ground wire are replaced by a voltage rectifier/regulator unit permitting a completely isolated AC circuit. WARNING Never secure electrical wires/cables with fuel lines. Keep wires away from any rotating, moving, heating, vibrating or sharp edge. Use proper fastening devices as required. 11-01-8 MMR2002_038_11_01A.FM 2002 SKANDIC LT 2002 SKANDIC LT BK/YL YL YL YL YL BL/BK BL/BK BK/YL YL YL YL BK/YL GR/BL GR/BK YL YL YL YL YL RD/BL RD/BL 0 BK/YL REVERSE SWITCH KEY SWITCH EMERGENCY KILL SWITCH BRAKE SWITCH DIMMER SWITCH 30A TACHO METER ON START L H BK YL/GN BK STARTER M POWER OUT CONNECTOR BK BK BK REVERSE LIGHT AND ALARM GR PARKING BRAKE SPEEDO METER BK HIGH BEAM INDICATOR OIL LEVEL INDICATOR SENSOR BK YL/GN YL/GN YL/GN YL/GN YL/GN YL/GN YL/GN YL/GN YL/GN A29Z08 YL/GN HEATED LEVER HEATED GRIPS TAIL LIGHT YL/GN BK FUSE .25A HEADLIGHT BK SOLENOID OR/GN BR BR WH RD/GN OR FUEL LEVEL METER BL RD WH/GR HEATED GRIPS AND LEVER SWITCH OIL LEVEL SWITCH OFF REGULATOR/ RECTIFIER MPEM TETHER CUT-OUT SWITCH 1 BK/YL 2002 SKANDIC WT LC RD/GN RD BK RD/GN RD RD RD STARTER START BATTERY FUSE 20 A STOP RD BK RD/GN RUN BK 2002 SKANDIC WT LC DESS ROM IGNITION SWITCH BK/GN BK/WH WH/GY BK RD/BL RD RD/GN BK/YL DC-OUTLET HEATED GRIP SWITCH BK/GN BL/YL BK/YL BK YL YL YL MPEM BK BK YL/GN YL/GN YL YL YL BK YL/GN BK/YL BK VI TEMPERATURE SENSOR BACK-UP ALARM SWITCH YL BK/GN REGULATOR RECTIFIER YL BK YL/GN BK BACK-UP ALARM AC YL YL YL YL WH/BL BK WH/GY BK/WH BK/YL BK/YL WH/YL BK/GY BK/WH WH/OR YL/GN WH/YL BL/YL RD/BL BK BK GN RD HEATED THROTTLE LEVER BK BK BK HEATED GRIPS BK BK YL/GN BK YL BL GY/VI LIGHT SWITCH BRAKE LIGHT SWITCH YL VI YL/GN BR HEADLAMP ENGINE OVERHEATING INDICATOR HIGH BEAM INDICATOR DESS INDICATOR FUEL LEVEL GAUGE YL/BK YL/GN GY RD/YL RD/YL GY WH/OR BK BL YL YL YL/GN BL WH/GY FUSE 0.25 A WH YL YL BL FUEL LEVEL SENSOR YL/BK A29Z07 GY WH WH YL/BK OIL LEVEL SENSOR YL RD/YL RESISTOR 30 OHM WH/RD YL/GN WH/RD BR YL WH/GY GY YL/GN YL YL YL/GN WH YL/GN TAILLIGHT EMERGENCY CUT-OUT SWITCH YL YL SPEEDOMETER OIL LEVEL INDICATOR 2002 SKANDIC WT/SWT STARTER START BK RD/GN RUN FUSE 20 A STOP BK RD RD/GN 2002 SKANDIC WT/SWT BK RD/GN RD RD RD STOP SWITCH DC-OUTPUT IGNITION SWITCH BK BK RD/BL RD RD/GN BK/YL BATTERY HEATED GRIP SWITCH YL/GN BK/YL RD/WH GN YL WH WH YL/BK YL YL YL BK IGNITION COIL COIL SUPPLY BACK-UP ALARM BACK-UP ALARM SWITCH YL YL/GN SPARK PLUGS GN YL YL AC YL BK/YL RD/WH BK BK BK/YL GENERATING COIL BK/YL BK HEATED THROTTLE LEVER BK BK/YL BK YL YL/GN BK/YL BK BK YL REGULATOR RECTIFIER GN RD BK BK BK YL/GN BK HEATED GRIPS BK WH BR YL/GN WH/GY GY YL BL YL/GN BL BL BRAKE LIGHT SWITCH BR BL YL/GN FUEL LEVEL GAUGE A29Z06 HEADLAMP HIGH BEAM INDICATOR SPEEDOMETER BR RD/YL YL/GN WH/GY BL YL YL YL/BK RD/YL GY GY YL/BK FUSE 0.25 A LIGHT SWITCH YL/GN FUEL LEVEL SENSOR RD/YL WH WH YL/BK OIL LEVEL SENSOR GY GY/VI YL RESISTOR WH/RD 30 OHM WH/RD BR YL YL YL WH/GY WH YL YL/GN GY YL YL/GN YL TAILLIGHT EMERGENCY CUT-OUT SWITCH YL YL OIL LEVEL INDICATOR