Disconnect four-way connector (6).

9.

Remove wire #4 from solenoid.
a.

Remove heat shrink from wire #4 (4) screw.

b.

Remove screw.

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1

1

2
3

2
1.
2.

Spring
Solenoid body
Figure 40. Install Spring

b.

See Figure 41. Hold spring (1) in place with suitable
holder (2). Suitable holder can be a popsicle stick,
cable tie or other thin flat object.

4
1.
2.
3.
4.

2070159

Plunger
Suitable holder
Spring groove
Solenoid body
Figure 42. Guide Plunger

2070168

4
3

2

2

1

1

Figure 43. Guide Plunger
1.
2.

Spring
Suitable holder
Figure 41. Suitable Holder

c.

See Figure 42 and Figure 43. Guide spring into spring
groove (3) of plunger (1) using suitable holder (2) to
hold spring in place.

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d.

See Figure 44. Remove suitable holder and insert
plunger (1) into solenoid body (2).

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2
1

2

1

3

1.
2.

Plunger
Solenoid body
Figure 44. Install Plunger

4.

See Figure 47. Install O-ring (1).

5.

Position lower bracket (2).

6.

Move solenoid toward installed position and install lower
screw (4) with lock washer (3). Tighten finger tight.

4

7.
NOTE
Verify O-ring is in pocket in reverse motor body under upper
bracket.
See Figure 49. Position upper bracket (3) between o-ring
(4) and reversing switch bracket (5).
8.

Install screw (1) with lockwasher (2).

9.

Tighten both screws.

1.
2.
3.
4.

Plunger
Spring groove
Spring
Solenoid body
Figure 45. Solenoid Components

Torque: 62–80 in-lbs (7–9 N·m) Reverse motor solenoid
screws

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1
1

4

2

1.

Lower screw
Figure 48. Solenoid Lower Screw

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1
3

4

2
5
3

1.
2.
3.
4.

Arm
Plunger
Spring groove
O-ring
Figure 46. Solenoid Plunger Install

1.
2.
3.
4.
5.

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4
3

Screw
Lock washer
Upper bracket
O-ring
Reversing switch bracket
Figure 49. Contactor Z Upper Bracket

Install Electrical Kit

2
1

1.

See Figure 50. Install bracket screw (13). Tighten.
Torque: 27–35 in-lbs (3–4 N·m) Reversing switch bracket
screw

2.

Attach wire #9 with ground screw (11). Tighten.
Torque: 62–80 in-lbs (7–9 N·m) Reversing switch ground
screw

3.
1.
2.
3.
4.

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O-ring
Lower bracket
Lock washer
Lower screw
Figure 47. Contactor Z Lower Bracket

Install timing relay.
a.

Position timing relay (9) on reverse motor (10).

b.

Install screws (14). Tighten.
Torque: 35–53 in-lbs (4–6 N·m) Reverse motor end
cap screws

c.

Route wiring between reverse motor and solenoid.

d.

Connect four-way connector (6).

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e.

Install wire #2 (2) on small solenoid stud.

g.

Install screws.

f.

Install nut. Tighten.

h.

Install nut. Tighten screws.

Torque: 13–18 in-lbs (1.5–2 N·m) Reverse motor
solenoid wire 2 nut
g.
4.

8.

Install new cable strap to secure harness leads to each
other.

9.

Install new cable strap to secure harness leads to each
other and reverse motor.

Install wire #4 (4) on solenoid.
a.

b.
5.

Install protective boot.

Torque: 9–13 in-lbs (1–1.5 N·m) Contactor Z cover
screws

Install wire #4 using screw. Tighten.
Torque: 9–13 in-lbs (1–1.5 N·m) Reverse motor
solenoid screw

NOTE
• Have left side cover removed to access main fuse.

Install new heat shrink over screw and terminal.

• If reverse motor runs continuous after actuation, remove
main fuse to stop rearward propulsion.

Connect reverse motor wires.
a.

Install reversing switch wire #7 (7) to lower reverse
motor stud.

b.

Install nut. Tighten.
Torque: 44–53 in-lbs (5–6 N·m) Reverse motor wire
#7 nut

c.

Install protective boot.

d.

Install reversing switch wire #12 (12) to upper reverse
motor stud.

e.

Install nut. Tighten.

• Remove solenoid and inspect for incorrect assembly of
spring if reverse motor runs continuous
10. Lift and support vehicle with wheels suspended in the air.
See service manual.
11. Verify reverse motor function by actuating reverse motor
a minimum of five times.
12. Remove vehicle from lift.
13. In a suitable area, verify reverse motor function by actuating
reverse motor a minimum of five times.

Torque: 44–53 in-lbs (5–6 N·m) Reverse motor wire
#12 nut
f.
6.

Install protective boot.

Install wires #8 and #5 on solenoid.
a.

Install wire #8 (8) on lower solenoid post.

b.

Install nut. Tighten.
Torque: 44–53 in-lbs (5–6 N·m) Reverse motor wire
#8 nut

7.

c.

Install protective boot.

d.

Install wire #5 (5) on upper solenoid post.

e.

Install nut finger tight.

Install contactor Z.
a.

Position wire #11 at lower position on Contactor Z.

b.

Install screw.

c.

Position wire #1 at upper position on Contactor Z.

d.

Install screw.

e.

Tighten both screws.
Torque: 13–18 in-lbs (1.5–2 N·m) Contactor Z wire
screws

f.

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Install cover.

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1

2

13
11

4
4

8

1

5

3

6

5

3
7

12

2

10

1.
2.
3.
4.
5.
6.
7.

7
14
6

9

Mounting screw (2)
Cover
Wire #1
Wire #11
Terminal screw (2)
Nut (2)
Contactor Z
Figure 51. Contactor Z

1.
Reversing switch
2.
Wire #2
3.
Solenoid
4.
Wire #4
5.
Wire #5
6.
Four-way connector
7.
Wire #7
8.
Wire #8
9.
Timing relay
10. Reverse motor
11. Ground screw
12. Wire #12
13. Bracket screw
14. Timing relay screw (2)
Figure 50. Reverse Motor Electrical Kit Connections

NEW LABOR CODE
Table 7. Labor Code
Item
Replace reverse electronic control
assembly, includes diagnosis.

Description
Reverse operates but pinion does not
retract.

Time Code

Time

1835

1.2 hours

Supplemental Procedure Video
WARNING
Always review the appropriate service procedure prior to
performing it. This video is intended to supplement, not
replace, documented service procedures. Attempting
service procedures without the proper training, tools,
equipment, and manuals could result in death or injury to
you or others. This could also damage the motorcycle or
cause the motorcycle to operate improperly. (10406a)
This video is a supplement of the procedure covered in the
document. This video can only be viewed through Service
Information Portal (SIP).

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Video 1. PINION EXTENDS BUT REVERSE MOTOR STALLS
OR SPINS SLOWLY

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