Speed Limiter System Testing; Module Wire Color Function - Polaris Trail Blazer Service Manual

ELECTRICAL
Speed Limiter System
Speed Limiter System Testing (LR44 - - Sportsman 335, Xplorer/Xpress 300, Trail Boss)
WARNING: The speed limiter is a safety feature and should never be disabled, except for testing purposes.
Serious injury or death may result if the limiter system is disabled.
When problems occur that sound like a spark-related "miss", the speed limiter system may be at fault. To
determine if the limit system is causing the problem, the system can be temporarily disabled.
1. Disconnect the black wire from the CDI module. The limiter system will then be disabled. If the problem still
exists, the limit system is not the cause. If the problem goes away, re-connect the black wire and proceed with
limiter system tests on the following pages. Verify all wires are clean and tight.

Module Wire Color Function

Refer to the model specific wiring diagram for wire colors. Modules may not have all wires indicated be-
NOTE:
low.
Black wire - provides ignition control to the CDI module
Green or Gray/Orange wire - receives reverse gear indicator light signal from purple wire through override button
White wire - receives a voltage signal from the ETC switch
Yellow/Red wire - receives the engine speed/ RPM signal from alternator
SYMPTOM
Limits in forward Limits in forward
High Limit
(Reverse Limit)
Low Limit
(ETC Limit)
Engine miss at idle or rough Engine miss at idle or rough
idle idle
Backfire on deceleration
(disappears when black wire
is disconnected from speed
limiter)
No limit in reverse No limit in reverse
Limits at wrong RPM Limits at wrong RPM
Polaris Sales Inc.
CAUSE
-Voltage to Green or Gray/Orange Voltage to Green or Gray/Orange
wire in forward gear i i f d g
-Voltage to white wire. Most often -Voltage to white wire Most often
caused by moisture in ETC switch. caused by moisture in ETC switch y
-Inadequate throttle cable tension. I Inadequate throttle cable tension. cable/ETC switch, or determine reason for voltage d h l bl
-ETC switch adjusted incorrectly -ETC switch adjusted incorrectly
-Idle speed adjusted incorrectly -Idle speed adjusted incorrectly
-ETC switch adjusted incorrectly
-Faulty ETC switch
-12V not present on Green or -12V not present on Green or
Gray/Orange speed limiter Gray/Orange speed limiter
module wire module wire
-Black wire from limiter module not -Black wire from limiter module not
connected to CDI module black connected to CDI module black
-Yellow/Red wire on limiter module Y ll /R d i li it
not receiving an RPM signal i i g RPM i g l
-Override switch not closing -Override switch not closing
-Faulty or incorrect limiter module Faulty or incorrect limiter module
-Improperly charged battery -Improperly charged battery
-Incorrect limiter module for Incorrect limiter module for
machine application machine application
-Incorrect alternator output Incorrect alternator output
-Faulty limiter module -Faulty limiter module
10.37
-Check circuit to determine reason for voltage to Check circuit to determine reason for voltage to
g green in forward gear i f d g
-Clean, dry, repair or replace the ETC switch -Clean dry repair or replace the ETC switch
assembly as required, inspect/adjust throttle assembly as required inspect/adjust throttle y q
i cable/ETC switch, or determine reason for voltage bl /ETC i h
on white wire
-Adjust ETC switch until switch plunger is completely -Adjust ETC switch until switch plunger is completely
depressed. No plunger Clearance. 1/16-1/8" throttle depressed. No plunger Clearance. 1/16 1/8 throttle
lever free play. (Readjust Idle)
-Adjust ETC switch until switch plunger is completely
depressed. No plunger Clearance.1/16-1/8" throttle
lever free play. (Readjust Idle)
-Dry out switch with electrical contact cleaner,
replace switch, or adjust throttle cable freeplay
-Check and repair reverse light circuit or gear -Check and repair reverse light circuit or gear
selector switch NOTE: if reverse light functions selector switch. NOTE: if reverse light functions
properly the gear selector switch is not the problem properly, the gear selector switch is not the problem
-Repair black wire between limiter and CDI -Repair black wire between limiter and CDI
d l -Check wiring and alternator output Ch k i i g d lt
-Test override switch function -Test override switch function
-Replace module Replace module
-Charge or replace battery -Charge or replace battery
-Check parts manual application Check parts manual application
-Check wiring and alternator output Check wiring and alternator output
-Replace limiter module -Replace limiter module
CURE
p j
d i f l
t t p t
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