Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 238 / 289

1. RAISE ATV WHEELS OFF GROUND AND
SUPPORT IN A SAFE MANNER.
2. MONITOR VOLTAGE AT HUB COIL
CONNECTOR, BETWEEN BROWN/WHITE
AND GROUND
TURN ATV
ON IN DIAGNOSTIC
MODE. TOGGLE TO TACH--
OMETER SETTING & REV ENGINE.
HOLD UNTIL DISPLAY STABILIZES.
DOES IT APPEAR
ACCURATE?
IS
SPEEDO
FUNCTIONING
CORRECTLY?
Y
CHECK
SPEEDO
(TEST NO. 2)
REMOVE 16 PIN
CONNECTOR FROM
BACK OF
INSTRUMENT
CLUSTER.
ENGINE IDLING
MEASURE AC VOLTAGE
BETWEEN PIN 7 AND
PIN 8.
OVER 3 VAC?
Y
REPLACE
SPEEDOMETER
N
CHECK CHARGING SYSTEM
(STATOR, REGULATOR,
AND WIRING)
N
TURN
AWD OFF.
START THE ENGINE
REV AND HOLD THE
RPM’S ABOVE 3100.
TURN AWD ON.
DOES FRONT
DRIVE
ENGAGE?
IS THE
AWD LIGHT ON?
MECHANICAL PROBLEM
N
INSPECT
HUB COIL WIRING
FOR SHORT CIRCUITS
TO GROUND. (DISCONNECT
CONNECTOR & MEASURE
BETWEEN HUB COIL
BROWN/WHT
& GROUND.)
REPAIR HUB COIL WIRING
REPLACE
SPEEDOMETER
NO PROBLEM
N
N
Y
Y
Y
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
NOTE: IF THE AWD LIGHT DOES NOT COME ON OR IF
12 VDC IS NOT REGISTERING AND AWD IS ENGAGING
ABOVE 3100 RPM,IT MAY BE A MECHANICAL PROBLEM.
TEST 4 -- NO AWD HUB SAFETY LIMIT
N
START HERE
TURN KEY SWITCH OFF
RESTART ATV
NOTE: IF THE AWD
LIGHT IS FLICKERING
RATHER THAN ON
CONTINUOUSLY,
THERE IS AN OPEN IN
THE HUB COIL.
ELECTRICAL
10.10
SPEEDOMETER TROUBLESHOOTING -- 2004 MODELS