Brake Warning System Overview; Brake Warning System Inspection; Hand Brake Master Cylinder Switch Inspection / Testing - Polaris Sportsman XP 1000 S 2020 Service Manual

BRAKE WARNING SYSTEM OVERVIEW

• This vehicle uses a brake monitoring system with half
plausibility check. This system uses a Mechanical
Switch that is integrated in the hand brake master
cylinder and a Brake Pressure Switch that is mounted
on the distribution block.
• For this system to operate correctly, the Brake
Pressure Switch needs to be activated before the
Hand Brake Master Cylinder Switch.
• These inputs can be monitored using Digital Wrench®.
If the hand brake lever is depressed slowly, you will be
able to monitor the change in the Brake Pressure
Switch before the Hand Brake Master Cylinder Switch
if the system is operating correctly.
• If the Hand Brake Master Cylinder Switch becomes
active and stays active for more than 3 seconds before
the Brake Pressure Switch changes status, the brake
warning light will illuminate to indicate a concern with
the system.
IMPORTANT
The brake warning light could illuminate and give a
false warning if the Hand Brake Master Cylinder Switch
becomes active but the system never builds pressure.
This can occur if the brakes are applied lightly or if the
hand brake lever is depressed and the system never
builds pressure.
• If the brake warning light is active, refer to the next
topic for testing procedures.
BRAKE WARNING SYSTEM
INSPECTION
1. Inspect the brake hydraulic system for any concerns.
If any leaks or mechanical failures are found with the
hydraulic system, concerns need to be repaired
before proceeding.
2. Connect the vehicle to Digital Wrench® and select
the Data Item Menu.
3. Add the Brake Pressure Switch and the Hand Brake
Master Cylinder Switch inputs to the main table.
4. Slowly depress the hand brake lever and observe the
switching point of the Brake Pressure Switch and the
Hand Brake Master Cylinder Switch.
5. When the hand brake lever is depressed, the Brake
Pressure Switch should become active before the
Hand Brake Master Cylinder Switch.
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
6. If the Hand Brake Master Cylinder Switch does not
change its status, check the Hand Brake Master
Cylinder Switch for mud or debris and also check for
free play on hand brake lever.
NOTICE
A sticking hand brake lever could also cause the brake
warning light to illuminate and give a false warning.
7. The brake warning light could also be caused by a
failed Brake Pressure Switch if any of the two
switches do not change status when monitoring on
Digital Wrench®. Refer to Brake Pressure Switch
Inspection / Testing page 10.20 for Brake Pressure
Switch testing. Refer to Hand Brake Master Cylinder
Switch Inspection / Testing page 10.19 for Hand
Brake Master Cylinder Switch testing.
8. If either of the switches fail the testing procedure,
check the electrical circuit for the switch that has
failed. It is possible that there could be a concern with
the circuit. If a circuit concern is found, repair or
replace as necessary.
9. If the electrical circuit passes testing, the failed switch
will require replacement.
10. If the concern is still present after previous testing has
passed, suspect there is a fault within the ECU.
HAND BRAKE MASTER CYLINDER
SWITCH INSPECTION / TESTING
The Hand Brake Master Cylinder Switch is integrated
with the Hand Brake Master Cylinder. When the hand
brake lever is depressed, the Hand Brake Master
Cylinder Switch will turn from inactive to active. This can
be monitored using Digital Wrench ®. If the status does
not change when the hand brake lever is depressed,
proceed with further testing.
1. Disconnect the electrical connector from the Hand
Brake Master Cylinder Switch.
2. Inspect the sensor and connector for moisture or
corrosion. If moisture or corrosion is found, clean the
sensor and connector.
3. With connector disconnected, check resistance
across pins on the sensor. When the Hand Brake
Master Cylinder Switch is closed (hand brake lever is
depressed), resistance should be less than 0.5 ohms.
When the Hand Brake Master Cylinder Switch is open
(hand brake lever is not depressed), resistance
should show as open (OL).
4. If the Hand Brake Master Cylinder Switch test fails,
resistance is not within specification and the switch
should be replaced.
BRAKE SYSTEM
10
10.19