Arctic Cat 2013 Prowler XT Service Manual page 157

The following is a list of conditions that can generate a
malfunction code. All conditions with the exception of
item 5 are external to the EPS assembly and therefore can
be cleared without replacement of the EPS assembly.
Make sure to thoroughly troubleshoot the entire system
before replacing the EPS assembly.
 NOTE: The EPS assembly is not serviceable and no
service parts or parts lists are available. The EPS is
only serviceable as an assembly and must not be dis-
assembled or EPS warranty will be voided.
CAUTION
Do not attempt to check resistance of the EPS motor
(2-pin input receptacle). There are internal capacitors
holding a charge that can cause internal damage to an
ohmmeter.
Malfunction code P0635 will appear if one of the follow-
ing six conditions occur:
1. Battery system power failure:
A. 30 amp EPS fuse blown
B. EPS relay failure
C. EPS voltage less than 8.5 DC volts for more than
two seconds
2. Ignition switch ON for more than five minutes with
the engine not running.
3. Vehicle Speed Signal Malfunction (engine speed
must exceed 2700 RPM for more than 60 seconds to
generate a malfunction code - timer resets if engine
drops below 2700 RPM).
A. Diode defective (open or shorted)
B. Diode not installed
C. Diode installed in reverse
D. Speed sensor defective
E. Speed sensor signal erratic
F. Speed sensor signal present but without engine
speed signal
G. Speed sensor power from LCD gauge interrupted
H. Incorrect LCD gauge installed
4. Engine Speed Signal Malfunction (vehicle speed must
exceed 5 MPH for more than two seconds - timer
resets if speed drops below 5 MPH.
A. No engine speed signal
B. Erratic engine speed signal
5. EPS Control Circuit Malfunction.
The following procedures may be helpful in determining
the source of a malfunction code:
Condition: Ignition Key Switch ON and NO EPS assist
when moving the handlebar. Code "P0635" flashing.
5-8
 NOTE: Prior to troubleshooting below, make sure
that Ignition Key Switch has not been left on with the
engine not started. After five minutes, this will deacti-
vate the EPS and display the malfunction code. Turn
Ignition Key Switch OFF and back to ON to reset and
reactivate the EPS. If code and symptom persists,
continue as follows:
1. Check 30 amp EPS fuse.
2. Check EPS relay (may be switched with any other
4-pin relay on PDM - replace relay if EPS normal
after switching).
3. Disconnect 2-pin connector on the EPS assembly
and connect a volt meter set to DC voltage to the har-
ness (black meter lead to BLK and red meter lead to
ORG/BRN).With the ignition switch to the ON posi-
tion, the meter must read more than 8.5 DC volts (if
correct voltage is not present, check connections and
wiring harness - if correct voltage is present, replace
EPS assembly - see Section 8).
CAUTION
Do not attempt to disassemble the EPS assembly as
there are no serviceable components within the assem-
bly and damage will occur voiding the EPS warranty.
Condition: Ignition switch ON and EPS assist normal
when moving handlebar. Code "P0635" flashing.
1. Check for speed sensor signal by disconnecting the
8-pin connector from the EPS assembly and using a
multi-meter set to the DC volt position, connect the
black lead to the PNK/YEL wire and the red lead to
the ORG wire. With the ignition switch turned to the
ON position, slowly move the vehicle forward or
backward. The meter must alternate from 0 DC volts
to approximately 12 DC volts. If meter readings are
not as specified:
A. Check EPS diode for correct installation or open
diode (replace diode or install correctly).
B. Check speed sensor using procedure found in this
section (replace speed sensor/install proper gauge).
2. Check for engine speed signal by disconnecting the
8-pin connector from the EPS assembly and using a
multi-meter set to the AC voltage position, connect
one lead to any BLK wire and the other lead to
YEL/VLT wire. Start the engine and with the engine
idling, the meter should read approximately 7.5 AC
volts. If meter reading is not as specified:
A. Check the wiring harness from EPS to gauge
(YEL/VLT wire - repair wiring).
B. Check the AC generator (see Section 5). If not to
specifications, replace the stator coil.
If after completing the above checks with normal results and
malfunction code "P0635" persists, the EPS assembly must
be replaced. To replace the EPS assembly, see Section 8.