Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 248 / 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
ATV IN NEUTRAL
ACTIVATE 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 ICON 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
NOTE: IF THE AWD ICON 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
Y
16 Pin Connector
1. Orange/White-- 12V Ignition Switch
2. Red/White-- 12V ETC and AWD Switch
3. Grey/Orange-- Mode/Override button
4. Black-- Ignition Kill
5. Green-- Diagnostic
(Factory Use Only)
6. Blue-- Diagnostic
(Factory Use Only)
7. Yellow/Red-- RPM Input
8. Brown-- Ground
9. Blue White-- Engine Overheat Switch
10. N/C
11. N/C
12. Purple/White-- Fuel Sender
(if equipped)
13. Brown/Red-- Trans Switch Ground
14. White-- Gear Shift Signal
15. N/C
16. Brown/White-- AWD Coil
ELECTRICAL
10.20
SPEEDOMETER TROUBLESHOOTING -- 2005 MODELS