Speedometer Operation Troubleshooting - Polaris SPORTSMAN 600 Service Manual

ELECTRICAL
SPEEDOMETER TROUBLESHOOTING
TEST 1 - - NO ALL WHEEL DRIVE
START HERE - -
ENGINE OFF
- - KEY SWITCH ON
- - TRANSMISSION IN LOW
- - AWD SWITCH ON
- - INSTRUMENT CLUSTER IN
DIAGNOSTIC MODE SET TO
AWD DIAGNOSTIC SCREEN
TURN ON AWD
SWITCH
DOES CLUSTER
SHOW
"ON"?
Y
ON HUB COIL
CONNECTOR
(LEAVE IT CONNECTED)
MEASURE FOR 12V FROM
BROWN/WHITE TO
GROUND
N
LEAVE AWD
SWITCH ON
TURN KEY SWITCH OFF
DISCONNECT 16 PIN
CONNECTOR FROM CLUSTER
TURN KEY SWITCH ON
CHECK FOR 12V
FROM BRN/WHITE
TO GROUND
Y
TURN KEY SWITCH OFF
RECONNECT CLUSTER
LEAVE HEADLIGHT POD
DISASSEMBLED
SHIFT TO LOW OR HIGH
LEAVE AWD ON
10.10
MECHANICAL
PROBLEM
Y
N
N
CLUSTER
READOUT
OK?
NOT AN INSTRUMENT
Y
CLUSTER PROBLEM;
CHECK AWD SWITCH
AND WIRING
N
WIRING
PROBLEM
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.
CHECK
INSTRUMENT
1. Red- - 12V Ignition Switch
CLUSTER
2. Red/White- - 12V ETC and AWD Switch
PROCEED
3. Grey/Orange- - Mode/Override button
TO TEST 2 4. Black- - Ignition Kill
5. Green- - Diagnostic
6. Blue- - Diagnostic
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
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.
Y
LEAVE KEY
SWITCH OFF
REMOVE THROTTLE
CONTROL COVER
DISCONNECT THROTTLE
CONTROL HARNESS
CHECK FOR CONTINUITY
ACROSS AWD
SWITCH
16 Pin Connector
(Factory Use Only)
(Factory Use Only)
REPLACE
INSTRUMENT
CLUSTER
PROCEED TO
MECHANICAL AWD
N
COMPONENTS
IF AWD PROBLEM
PERSISTS.