Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 239 / 289

CHECK
SPEEDOMETER
INSTRUMENT
CLUSTER FUNC-
TION OK?
CHECK FUEL &
IGNITION SYSTEMS
REPLACE
SPEEDOMETER
N
Y
TEST 5 REVERSE SPEED LIMITER ACTIVATED IN FORWARD GEAR
REMOVE 16 PIN
PLUG FROM BACK OF
INSTRUMENT
(PERFORM TEST 2)
PROBLEM
REMAINS?
SHIFT TO LOW OR HIGH
GEARS. IS REVERSE INDICA-
TOR LIGHT ON OR GEAR ON?
(Engine loses spark when vehicle speed is above 7-9 mph.)
TEST TRANSMISSION SWITCH
CHECK RELATED WIRING
TEST 6 WHEEL SPEED SENSOR
Tools Required:
G
Static Timing Light Harness (PN 2871745)
G
Hall Sensor Probe Harness (PN 2460761) or equiva-
lent jumper wires.
To test wheel speed sensor:
1.Disconnect 3 Pin connector from speedometer.
2. Connect wires from test light to sensor 3 Pin
connector as shown at right, using the Hall Sensor
Probe Harness (PN 2460761) or jumper leads.
3. Elevate front right side of vehicle until tire is off the
ground.
4. Slowly turn right front wheel while observing the
test light.
5. If light flashes, sensor is O.K. Be sure connections
are good and 9 volt battery is in good condition.
9V
-- +
Static Timing Light Harness
LED
Brn
To Sensor Red
To Sensor
White
To Sensor
Black
680
Ω
Wht
Blk
START HERE
( PN 2871745 )
Y
N
CLUSTER
NOTE: OVERRIDE SWITCH PLAYS NO ROLE IN
REVERSE GEAR OUTPUT ON THE ATV.
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
DOES THE LETTER “E”
APPEAR?
TURN KEY SWITCH OFF
RESTART ATV AND
TEST DRIVE
WHEEL SPEED
SENSOR LOCATION
ELECTRICAL
10.11
SPEEDOMETER TROUBLESHOOTING -- 2004 MODELS