Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 236 / 289

CHECK
SPEEDOMETER
-- KEY SWITCH ON
-- TRANSMISSION IN
NEUTRAL
-- AWD SWITCH ON
N
Y
TEST 1 -- NO ALL WHEEL DRIVE
Note : If AWD light comes on, instru-
ment cluster is O.K. Proceed to me-
chanical tests (in Service Manual).
Shade the AWD light with your hand to
verify it’s operation. The AWD switch is
directly powered by switched 12 volts
(red/white). The gear switch only inter-
faces with the instrument cluster. To en-
able AWD, the cluster must be display-
ing low or high gear, or reverse gear with
the override button pushed in.
(PERFORM
TEST 2)
SPEED
READOUT
OK?
START HERE
ON HUB COIL
CONNECTOR
(LEAVE IT CONNECTED)
MEASURE FOR 12V FROM
BROWN/WHITE TO THE
COIL BODY
(GROUND)
NOT AN INSTRUMENT
CLUSTER PROBLEM;
CHECK AWD SWITCH
AND HUB COIL
N
LEAVE AWD
DISCONNECT 16 PIN
CONNECTOR FROM CLUSTER
CHECK FOR 12V
FROM BRN/WHITE
TO GROUND
Y
Y
SWITCH ON
RECONNECT CLUSTER
LEAVE HEADLIGHT POD
DISASSEMBLED
SHIFT TO LOW OR HIGH
LEAVE AWD ON
Y
REMOVE THROTTLE
CONTROL COVER
CHECK FOR CONTINUITY
ACROSS AWD
INDICATOR BULB
Y
REPLACE
INSTRUMENT
CLUSTER
BAD AWD BULB.
PROCEED TO
IF AWD PROBLEM
PERSISTS.
MECHANICAL AWD
COMPONENTS
N
1. Red-- 12V Constant
2. Red/White-- 12V Switched
3. Grey/Orange-- Mode/Override button
4. Black-- Ignition Kill
5. N/C
6. N/C
7. Yellow/Red-- RPM Input
8. Brown-- Ground
9. Blue White-- Engine Overheat Switch
10. Purple/Yellow-- Oil Pressure Switch
11. Orange/Red-- Park Gear
12. Purple-- Reverse Gear
13. Green/White-- Neutral
14. White/Blue-- Low Gear
15. Blue/Red-- High Gear
16. Brown/White-- AWD Control
16 Pin Connector
WIRING
PROBLEM
N
TURN KEY SWITCH OFF
TURN KEY SWITCH ON
TURN KEY SWITCH OFF
LEAVE KEY
SWITCH OFF
DISCONNECT THROTTLE
CONTROL HARNESS
Note : Reversing polarity when connecting
the battery or other DC power source
backwards will fail the AWD control and
the instrument cluster If the key switch
and the AWD switch are turned on.
ELECTRICAL
10.8
SPEEDOMETER TROUBLESHOOTING -- 2004 MODELS