Speed Limiter System Testing; Module Wire Color Function - Polaris Magnum 2x4 Service Manual

ELECTRICAL
Speed Limiter System
Speed Limiter System Testing
CAUTION: (except 1997 Scrambler 500) The speed limiter control module may be permanently
damaged if the machine is operated with the voltage regulator damaged and/or the battery disconnected.
WARNING: The speed limiter is a safety feature and should never be disabled, except for testing purposes.
Serious injury or death may result if the limiter system is disabled.
When problems occur that sound like a spark-related "miss", the speed limiter system may be at fault. To
determine if the limit system is causing the problem, the system can be temporarily disabled.
1. Disconnect the black wire from the COl module. The limiter system will then be disabled. If the problem still
exists, the limit system is not the cause. If the problem goes away, re-connect the black wire and proceed with
limiter system tests on the following pages. Verify all wires are clean and tight.
Module Wire Color Function
NOTE:
Refer to the model specific wiring diagram for wire colors. Modules may not have all wires indicated below.
Black wire - provides ignition control to the COl module
Green or Gray/Orange wire - receives reverse gear indicator light signal from purple wire through override button
White wire - receives a voltage signal from the ETC switch
Yellow/Red wire - receives the engine speed/ RPM signal from alternator
SYMPTOM CAUSE CURE
Limits in forward
High Limit
-Voltage to Green or Gray/Orange -Check circuit to determine reason for voltage to
(Reverse Limit)
wire in forward gear green in forward gear
Law Limit
-Voltage to white wire. Most often -Clean, dry, repair or replace the ETC switch
(ETC Limit)
caused by moisture in ETC switch. assembly as required, inspect/adjust throttle
-Inadequate throttle cable tension. cable/ETC switch, or determine reason for voltage
on white wire
Engine miss at idle or rough -ETC switch adjusted incorrectly -Adjust ETC switch until switch plunger is completely
idle
-Idle speed adjusted incorrectly
depressed. No plunger Clearance. 1/16-1/8" throttle
lever free play. (Readjust Idle)
Backfire on deceleration -ETC switch adjusted incorrectly -Adjust ETC switch until switch plunger is completely
(disappears when black wire depressed. No plunger Clearance.1 /16-1 /8" throttle
is disconnected from speed lever free play. (Readjust Idle)
limiter)
-Faulty ETC switch
-Dry out switch with electrical contact cleaner,
replace switch, or adjust throttle cable freeplay
No limit in reverse -12V not present on Green or -Check and repair reverse light circuit or gear
Gray/Orange speed limiter selector switch. NOTE: if reverse light functions
module wire properly, the gear selector switch is not the problem
-Black wire from limiter module not -Repair black wire between limiter and COl
connected to COl module black
-Yellow/Red wire on limiter module
-Check wiring and alternator output
not receiving an RPM signal
-Override switch not closing -Test override switch function
-Faulty or incorrect limiter module -Replace module
Limits at wrong RPM -Improperly charged battery -Charge or replace battery
-Incorrect limiter module for -Check parts manual application
machine application
-Incorrect alternator output
-Check wiring and alternator output
-Faulty limiter module -Replace limiter module
12/97
10.34
Polaris Industries Inc.