Polaris 2004-2005 Sportsman 6x6 Service Manual page 238

ELECTRICAL
SPEEDOMETER TROUBLESHOOTING - - 2004 MODELS
TEST 4 - - NO AWD HUB SAFETY LIMIT
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.
OMETER SETTING & REV ENGINE.
HOLD UNTIL DISPLAY STABILIZES.
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
AWD OFF.
START THE ENGINE
REV AND HOLD THE
RPM'S ABOVE 3100.
TURN AWD ON.
DOES FRONT
DRIVE
ENGAGE?
Y
IS THE
AWD LIGHT ON?
N
MECHANICAL PROBLEM
10.10
TURN ATV
ON IN DIAGNOSTIC
MODE. TOGGLE TO TACH- -
DOES IT APPEAR
ACCURATE?
N
TURN KEY SWITCH OFF
REMOVE 16 PIN
CONNECTOR FROM
INSTRUMENT
CLUSTER.
NOTE: IF THE AWD
LIGHT IS FLICKERING
RATHER THAN ON
CONTINUOUSLY,
THERE IS AN OPEN IN
THE HUB COIL.
N
NO PROBLEM
Y
START HERE
SPEEDO
Y
FUNCTIONING
CORRECTLY?
MEASURE AC VOLTAGE
BETWEEN PIN 7 AND
BACK OF
16 Pin Connector
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
INSPECT
HUB COIL WIRING
FOR SHORT CIRCUITS
TO GROUND. (DISCONNECT
CONNECTOR & MEASURE
BETWEEN HUB COIL
BROWN/WHT
& GROUND.)
Y
REPAIR HUB COIL WIRING
IS
N
CHECK
SPEEDO
(TEST NO. 2)
RESTART ATV
ENGINE IDLING
Y
PIN 8.
OVER 3 VAC?
N
CHECK CHARGING SYSTEM
(STATOR, REGULATOR,
AND WIRING)
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
N
REPLACE
SPEEDOMETER
REPLACE
SPEEDOMETER