Testing For Intermittent Conditions; Testing Current Flow (Amperage) - Polaris RZR PRO XP 2020 Service Manual

TESTING FOR INTERMITTENT CONDITIONS

Intermittent conditions are very difficult to diagnose, as
when you are testing the circuit, you may not have the
circuit failing to indicate where the issue is. Intermittent
electrical failures are almost always related to a poor
connection that only goes open in specific situations,
such as going over a certain kind of bump, at a certain
temperature, or when the machine is torque loaded in
one way.
Here is a list of possible failures that can be associated
with an intermittent electrical failure:
• Loose female terminal in an electrical connector.
NOTICE
If the terminals in question are the correct size/series,
always use PV–43526 to test the drag when inserting
and removing the test terminal adapters. Compare the
effort to the drag against the known good tester
terminal for reference.
• Poor terminal to wire crimp.
• Terminal crimp that occurred at least partially on
insulation instead of the conductor wire strands.
• Terminal fretting corrosion
• Contamination/moisture corrosion
• A full or partial break of the conductor wires in the
insulation, with or without visible insulation damage.
• Improper routing, especially when it leads to chaffing
or heat damage, especially near exhaust.
You may need to use different techniques to duplicate
these concerns. These include but are not limited to:
• Moving the harness by wiggling it or flexing certain
areas.
• Pulling at or near the suspected connector.
• Pushing in different directions to flex the connector
body and try to isolate poor connections.
• Changing the temperature. This can be accomplished
with either heat guns or cold air guns.
WARNING
Always exercise caution when using these tools, and
use them for short periods of time when changing the
temperature of an area. Failure to do so can lead to
serious injury and/or damage to the machine.
9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc.
GENERAL INFORMATION

TESTING CURRENT FLOW (AMPERAGE)

Performing a current flow test requires the meter leads
be inserted into the correct cavities in the meter, and be
placed in series in the circuit to be tested. Refer to your
Digital Multi Meter's owner's manual for potential model
specific instructions. Ensure you are using acceptable
adapters to avoid damaging the connector terminals.
See Connector Probing Guidelines page 1.74.
NOTICE
Amperage specs are generally not provided for circuits/
components. Please only perform this test when
advised in the manual.
IMPORTANT
Many circuits on this machine will exceed the 10 Amp
fuse in most Digital Multi Meters in normal operation.
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