Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 246 / 289

CHECK
INSTRUMENT
CLUSTER
PROCEED
TO TEST 2
-- KEY SWITCH ON
-- TRANSMISSION IN LOW
-- AWD SWITCH ON
-- INSTRUMENT CLUSTER IN
DIAGNOSTIC MODE SET TO
AWD DIAGNOSTIC SCREEN
N
Y
TEST 1 -- NO ALL WHEEL DRIVE
Note : If AWD icon comes on, instru-
ment cluster is O.K. Proceed to me-
chanical tests (in Service Manual).
Check the AWD icon on instrument clus-
ter to verify it’s operation. The AWD
switch is directly powered by switched
12 volts (red/white). The gear switch
only interfaces with the instrument clus-
ter. To enable AWD, the cluster must be
displaying low or high gear, or reverse
gear with the override button pushed in.
START HERE --
ENGINE OFF
ON HUB COIL
CONNECTOR
(LEAVE IT CONNECTED)
MEASURE FOR 12V FROM
BROWN/WHITE TO
GROUND
NOT AN INSTRUMENT
CLUSTER PROBLEM;
CHECK AWD SWITCH
AND WIRING
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
SWITCH
Y
REPLACE
INSTRUMENT
CLUSTER
PROCEED TO
IF AWD PROBLEM
PERSISTS.
MECHANICAL AWD
COMPONENTS
N
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 will
fail the AWD control and the instrument
cluster If the key switch and the AWD
switch are turned on.
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
16 Pin Connector
MECHANICAL
PROBLEM
TURN ON AWD
SWITCH
DOES CLUSTER
SHOW
“ON”?
CLUSTER
READOUT
OK?
N
ELECTRICAL
10.18
SPEEDOMETER TROUBLESHOOTING -- 2005 MODELS