2011 SPORTSMAN 850 Chapter 12 - the Polaris International Extranet
Contents
1. oye RD BN TON on m 1 Im dn R e 8US CHASSIS POWER gt m LEFT ton BH RIGHT CHASSIS POWER e er RT HEADLIGHT HEADLIGHT ROHT 8 T D E YE D6 f LOCATED BELOW HANDLEBARS RUNNING RUNNING lt us LIGHT LIGHT BUS A 1 LIGHTS 20 A f E eo i LOCATED ON 117 1 moo LIGHTS Br mm LI wes SPLICE AIR INTAKE BOX amp 5555 LEFT RIGHT GROUND 3 HEADLIGHT HEADLIGHT ec SPLICE BN SPLICE SPLICE CAVITY FOR 850 64 CAVITY FOR 550 35 i BN 8 e LOW BEAM T D6 1 spuce 06 GROUND 2 T BN SPLICE T 06 1 062. Br iE i NOILINSI YOLOSNNOD AME SAU Sog H Old VIN 013115 Tans it 8 4 0 ee CX CR 570 S lb c aNnou9 18 04 es 08 33VINI JO 301 e 031201 I 109 NOLLINSI 135 8908 0131 5 o EE 5 a ez 0 iT TIN 001 068 801 ALIAVD 2 TINI 543 068 04 E 1 2X 058 603 ALIAVD T 9001 068 304 ALIAYO ez 943 068 404 gt 1304 B dX 058 ALIAVD S5 ua3l3A0d33ds vy 405815 11431 1303 2 309 1411 1304 5 YOSNaS ic Nid 93 Ho AER BIS 1604 Us
3. LH RH oat FRONT FRONT Lb zeppe SIGNAL FLASHER 20A INI selavesese CHASSIS POWER pes 5 28 45 aa LIGHTS B RD BN SPLICE a sl LE lt s LEFT HANDLEBAR SWITCH ASSY L A YE DG H B B BU RD J DB RD gt LEFT RIGHT C RD GN K GY RD HEADLIGHT HEADLIGHT D RD BK 1 06 SPLICE SPLICE F GY OG M B F RD N B th 6 06 P YE 2 s GROUND 3 1 HJ UI IK L M N P i L_py alli ea DB RD GROUND A LOW BEAM O FLASH PASS O TURN NER GROUND 4 py R TURN oto GROUND L SPLICE REV OVERRIDE HAZARD HORN O RUN z GROUND 2 2 BU YE B SPLICE 5 2 BU WH DB WH LH REAR RH REAR TURN SIGNAL TURN SIGNAL CAVITY FOR 550 EPS INTL 21 22 CAVITY FOR 550 TOUR INTL T 8 CAVITY FOR 550 X2 INTL 1 8 CAVITY FOR 850 EPS INTL 21 22 CAVITY FOR
4. SPEEDOMETER CAV FO 550 X 2 NOTE POWERED TO UNLOCK D TAL GROUND B CAVITY FOR 550 EPS 5 AC MM E OF BATTERY CAVITY FOR 550 TO 2 SECOND SOLENOID OF BATTERY CAVITY FOR 550 X2 2 TURF n CAVITY FOR 850 X 2 UNDER CAVITY FOR 850 EPS 5 MR ee CAVITY FOR 850 TO 2 REA i CAVITY FOR 850 X2 2 SOLENOID G WH CAVITY FOR 550 EPS INTL 5 RELAY vr DON CAVITY FOR 550 TOUR INTL 2 qoe CAVITY 4 FOR 550 X2 INTL 2 POWER CAVITY FOR 850 EPS INTL 5 a ADC CAVITY FOR 850 TOUR INTL 2 COIL 20 2 LOW F 5 SPLICE 0 6 AWD an COIL co HGH DRIVE SPLICE SPLICE ao 5 BN WH 9 AWD ADC GY GN n RE PNE GROUND amp o LOCATED IN FRONT 5 CAVITY 4 FOR 550 41 48 0 26 50 29 5 e CAVITY 4 FOR 850 10 Hl 46 63 16 47 18 2 NEM ICON 7 21509 SWITCH RIGHT HANDLEBAR 5 ga SWITCH LOCATED ON E 46409 ASSEMBLY LEFT SIDE OF lm c AIR INTAKE BOX GY 6 i gt G 9 BK RD 7
5. AHOSS322V ZH 4 we Mios 5 NG HM 90 82165 Ng h 3310 HM 90 1 A80SS393V uw I l 8 55 08 ooo cy 031 201 im 079 1 AHOSS322V HM 90 PEE EUN ETC far 310 uv3u ch 0117201 LHOITMNVL HM LHOMIIVL HA 2n XATEINSSSVY HOLIMS L HOLIMS 3yVug 1H9lH PRIN PLN i u 101883 0 3801 e d 20 n A d _ 1543439 SAGE rt gt 00345 LI os 4 m 410 NAY 110 ex bad E 9 99V n z 0 ME S o J 30 19 8 lx 3425 01 1 2272 39 18 H H91H Ov EE 55 HOLIMS 1102 uVSTTONVH 1441 ENA pe 2 18 SLHON SISSVHO GL Nid N93 OL 3UIM 04 90 1068 04 90 09 90 22 2 V GNNOYD 01 181 NG 056 8 Ng q 1102 25 voz voz voz S3l0SS333V SIHIN 63 Le 2 90 N9 0Y Hr
6. FAN CIRCUIT BU YE dz IGNITION SWITCH BREAKER ASH NH RD o 5 j 0 ie F Locate BELOW HANDLEBARS 89 B8 i BUSE PN Imi GROUND A e START SOLENOID RELAY if R S Bi SPLICE Bee SEE KEY ON WH RD E DN WH RD 06 gt lt Su REDI 06 BRAKE DIODE LIGHTS 5 9O PARK RD BN SPLICE i B le REV CHASSIS POWER i T na ASSIS Vd BRAKE SWITCH iH CLOSED WITH HAND BRAKE APPLIED GEAR SELECTOR SWITCH LOCATED AT LEFT RESISTOR MODULE CONTROL LOCATED BELOW HEAD LAMP 06 300 OHM RESISTOR MODULE B 620 OHM WH SPLICE SPEEDOMETER ECM SIGNAL GROUND CAN HIGH CAVITY FOR 850 XP EE SPLICE SPLICE CAVITY FOR 850 EPS 4 5 CAVITY FOR 850 TOUR 2 on CAVITY FOR 850 X2 1 2 YE GN i THE ECM WILL ALLOW CRANK CONNECT E pomme PIN 70 WIRE E70 TO GROUND IF THE TRANSMISSION IS 33 64 10 38 10 11 A PARK OR B NEUTRAL OR ECM 2 THE BRAKE SWITCH IS ACTIVATED AND 3 THE ENGINE 1 NOT RUNNING 12 44 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc EL
7. T E P WINCH perpe _ RE 4 SWITCH o 0 3 POWER IINE ay t LOCATED BELOW HANDLEBARS amp KEY ON _ 3 BUS BUS WH c 8 E4 8D 6N C2H 06 WH 06 09 ref e Cg LIGHTS ACCESSORIES 20 204 20 COIL 10 109 pa BN BN 550 BN WIRE TO GROUND 3 SPLICE 55 20 RELAY D8 RD DB RD 950 DB RD WIRE TO PIN 75 55 UGHTS RD BN SPLICE iN AWD ees d COIL 1 240 CLOSED WHEN qe BRAKE APPLIED BRAKE SWITCH T ji BN WH Spat AWD ADC GY N D E GROUND B EE T l 1 RADIATOR POD ACC 21502 1 al 46409 15 2 RD GN ER ES 2 22 5 E e 2X4 4X4 2X4 500 869 E 2 RIGHT HANDLEBAR SWITCH ASSEMBLY I BULKHEAD 2 BULKHEAD 28 ACCESSORY 1 Bt ACCESSORY LH TAILLIGHT RH TAILLIGHT SPLICE 12 47 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL
8. 8 10 FtLoCAT TION SWITCH ED B HI ELOW HANDLEBARS R S B SPLICE THESE CIRCUITS SHOULD ALL BE NEAR BATTERY VOLTAGE WHEN THE KEY SWITCH AND RUN STOP SWITCH ARE ON VOLTAGE WHEN THE BATTERY 1 CONNECTED pou eu E ON DIAGNOSTIC LOCATED UNDER L FRONT RACK T LEFT HANDLEBAR i SWITCH ASSEMBLY 2 5 LO dT r OFF M Oy pt 7 a o ae 5 OFF RUN OFFI xe A 5 SPEEDO 421 REVERSE 6 OVERRIDE 06 S CAVITY FOR 550 34 CAVITY FOR 850 26 85 B4 5 RELAY lt gt WAKE UP COMMAND LOCATED ON LEFT SIDE OF AIR INTAKE BOX c9 e 8 D9 08 12 42 CHASSIS RELAY 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc R es es SPEED
9. Chassis Relay EFI RELAY Color Function Color Function RD Fuse link protected 12 Vdc battery RD GRN 20A fuse protected 12 Vdc battery voltage voltage DB RD ECM control circuit for relay coil GRN YEL Relay coil ground from ECM LH RUN switch supplied 12 Vdc battery LH RUN switch supplied 12 Vdc battery ORG ORG voltage to relay coil voltage to relay coil 12 Bus bar for 12 Vdc power splice for Lights 20A Fuse Ignition coil pack Drive 20 Fuse eee Fuel Pump Accessory 20A Fuse Fuel Injectors 12 22 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Bumper Lights Relay The bumper lights relay provides power to the following system Front Bumper Head Lights Bumper Lights Relay Color Function RD BRN 20A fuse protected 12 Vdc battery voltage BRN Ground for relay coil DG High Low LH control 12 Vdc battery voltage to relay coil DG LH RH front bumper lights power Start Solenoid Relay The start solenoid relay provides power to the following system Starter Motor Solenoid Start Solenoid Relay Color Function RD WHT 10A circuit breaker protected 12 Vdc battery voltage BRN WHT control for relay coil WHT RD Starter solenoid power Key switched START relay coil power 12 battery voltage Power Steering Relay EPS Models N
10. 12 36 INSTRUMENT CLUSTER NO INCORRECT FUEL LEVEL 12 37 ELECTRONIC POWER STEERING EPS EPS OPERATION p 52 ertt de EE De e Og Neu a 12 38 EPS 8 WAY WIRE HARNESS 12 38 PROPER EPS SYSTEM DIAGNOSING EPS CIRCUIT 12 38 EPS TROUBLESHOOTING eR ERI Lm bd e 12 39 ELECTRICAL BREAKOUT 5 BATTERY CHARGING 5 2 12 40 CONSTANT POWER 5 12 41 KEY ON POWER 12 42 KEY ON POWER CIRCUITS INTL MODELS 12 43 ENGINE START COMMAND AND GEAR SWITCH CIRCUITS 12 44 ENGINE START COMMAND AND GEAR SWITCH CIRCUITS INT L MODELS 12 45 CHASSIS POWER 12 46 CHASSIS POWER CIRCUITS INTL MODELS 12 47 WAKE UP COMMAND AND FUEL PUMP FUEL LEVEL CIRCUITS 12 48 TURF AND GROUND SPEED SENSOR 5 12 49 LIGHT CIRCUIT S t e eae oN aed n ec 12 50 LIGHT CIRCUITS INTL 5 12 51 TURN SIGNALS HAZARD LIGHTS INT L 5 12 5
11. SWITCH AND RUN STOP SWITCH ARE ON LEFT HANDLEBAR SWITCH ASSY at s ts 4012435 PE L 5 2 Cz ue zz F C HHH 8 2 0 E E 6 K L IM N SPEED A B C D E FIG H J KIL MIN P SENSOR HI BEAM O LOW BEAM FLASH PASS TURN O R TURN oto REV OVERRIDE HAZARD HORN o RUN m M GT Sp 06 1 m c E B 4 Sos m nee m CAVITY FOR 550 34 2 CAVITY FOR 850 26 eee B5 B4 Z LOCATED ON lt RELAY i LEFT SIDE OF ap AIR INTAKE BOX MIIE EA c3 os r1 2 Lase D9 D8 SPEEDOMETER CHASSIS RELAY 12 43 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Engine Start Command and Gear Switch Circuits 850 DOMESTIC ENGINE CRANK amp GEAR SENSE JEH 20100707
12. 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL CHARGING SYSTEM Charging System Diagram The charging system consists of Battery Stator Alternator Voltage Rectifier Regulator Voltage Rectifier Regulator 600 Watt The voltage rectifier regulator is responsible for converting AC voltage to DC voltage and controls the DC output NOTE If the temperature of the regulator rectifier exceeds 194 F 90 C the unit will turn itself off to cool down The unit will turn on at approximately 167 F 75 C If voltage output is equal to or less than static battery voltage verify the housing cooling fins are clean free from debris and that adequate airflow is present Current Draw Key Off CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running Damage will occur to electrical components Connect an ammeter in series with the negative battery cable Check for current draw with the key off If the draw is excessive loads should be disconnected from the system one by one until the draw is eliminated Check component wiring as well as the component for partial shorts to ground to eliminate the draw Current Draw Inspection Key Off Current Draw Key Off Maximum of 01 DCA 10 mA Battery Charge Test CAUTION Do not allow the battery cables to become disconnected with the
13. een 12 17 ELECTRONIC THROTTLE CONTROL 12 18 GEAR SELECTOR SWITCH esc DA E pk ERR ara 12 18 GREED SENSOR es ques rubei tasa 12 19 REAR DIFFERENTIAL SOLENOID 2 12 20 AWD ADO COES 12 21 12 22 CHASSIS EFI 12 22 BUMPER LIGHTS START SOLENOID POWER STEERING RELAY 12 23 REAR DIFFERENTIAL SOLENOID RELAY X2 5 12 23 FUSES nase vo padus Roam 12 24 BOMLAVOUN Potens eM onum tent 12 24 ING ental GaSe casa EA 12 25 HEADLIGHT BUMPER LAMP 12 25 HEADLIGHT BUMPER LAMP REPLACEMENT 12 26 TAIL BRAKE BULB 12 26 CHARGING 5 5 12 27 CHARGING SYSTEM 12 27 VOLTAGE RECTIFIER REGULATOR 600 12 27 CURRENT DRAW KEY OFF BATTERY CHARGE TEST 12 27 STATOR ALTERNATOR 5 5 12
14. information area 2 Press and hold the MODE button until the information display area begins to flash 3 Toggle the SELECT button to increase the service interval hours in 5 hour increments to a maximum of 100 hours 4 To turn off the service interval function toggle the SELECT button until OFF is displayed Clock The clock displays the time in a 12 hour or 24 hour format Change between 12 hour and 24 hour formats by performing the following procedure 1 Press and hold the MODE button until RPM is displayed 2 Toggle the SELECT button until the odometer is displayed 3 Press and hold the MODE button until the clock displays the new hour format To view the clock when the key is out of the ignition switch press the MODE button The current time will be displayed for approximately 10 seconds There are two methods for setting the clock Method 1 1 Toggle the SELECT button until engine hours is displayed 2 Press and hold the MODE button until the clock begins to flash 3 Press and release the SELECT button to change the hours 4 Press and release the MODE button to move to the next position The minutes are set in the same manner 5 When the time is no longer flashing the clock has been set 12 7 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Method 2 4 first number is located in the information area and can be 2 to 6 di
15. qu RD WH WILL READ APPROXIMATELY 0 7 RD WH VOLTS BELOW BATTERY VOLTAGE FUSE LINK 2 SPLICE RD EN Mu dE as FUSE LINK 4 a SPLICE gt JGNITION SWITCH A9 9 48 e o io 4 9 B8 START SOLENOID L RELAY RD GN BUS 01 D6 04 EFI UNSWITCHED 20A 10A BUS RD BK RD WH REVERSE POLARITY DIODE RD WH PROVIDES POWER EPS RELAY JON WAKE UP SHEET Pu AT e 5 223 230 D3 D2 RD RD 3 A COL 5 5 5 30A 214 USED WITH POWER I J STEERING ji I 12 41 9923067 2011 850 Copyright 2010 Polaris Sales Inc ELECTRICAL Key On Power Circuits JEH 20100707 KEY SWITCH AND RUN STOP SWITC THIS CIRCUIT SHOULD BE NEAR BATTERY DOMESTIC POWER CIRCUITS POWERED DIRECTLY BY T HE H
16. 00706 METE WE eas Hig cin r 2 2 3 89 00713079 1103 059 120 L HL 1 2 E CO 51538 13411 UR E d 5 3 dnd 7905 180 D W34 3045 ayina 999 Uc RUIN NN LL _ 95 D 381983 JHL 3 V LUYIS OI SIN3NOdNOO 18553238 IHL INIYIMOd 39 010045 3H 1104 STHL F 144 1 92 ra C fg 01230NI 1304 ONY 1102 C 714 NOILINDI 1303 IHL 27194383 OL AV13 133 JHL SNYNI N23 JHL 4058435 NOILISO YU JHL NO NOILON 5315 NOJ JHL 6 08 e EW 90 SIIYW ONY 430 4138 143 IHL SNYNL 90 NO 433 JHL W31SAS 1303 IHL 3719155334 ONY 1303 JHL NAY OL 50802352 301 AVTSY 133 011231084 30010 SNYML JHL HOIH 309 92 Nid Z OYTE 083 31391 33104 TIIM HO3 JHL NO 1001185 dOLS NNY NV AIM HOIH SI 92 Nid I 7 Tans 9 N23 098 10100102 Lu 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc 12 48 ELECTRICAL JEH 20100707 AWD ADC TURF amp GROUND SPEED
17. 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL OCV Open Circuit Voltage Test Battery voltage should be checked with a digital multitester Readings of 12 6 volts or less require further battery testing and charging See the following chart and Load Test NOTE Maintenance Free batteries should be kept at a high state of charge during storage If the battery is stored or used at a low state of charge hard crystal sulfation will form on the plates reducing the efficiency and service life of the battery NOTE Use a volt ohm meter to test battery voltage Battery PN 4011496 OPEN CIRCUIT VOLTAGE State of Charge Maintenance Free 10096 13 0 V 75 Charged 12 8 V 5096 Charged 12 5 V 2596 Charged 12 0 V 096 Charged 11 5 V or less Load Test CAUTION To prevent shock or component damage remove spark plug high tension leads and connect securely to engine ground before proceeding A battery may indicate a full charge condition in the OCV test but still may not have the storage capacity necessary to properly function in the electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is encountered To perform this test use a load testing device that has an adjustable load Apply a load of three times the ampere hour rating At 14 seconds into the test check battery voltage good 12V batt
18. 27 STATOR ALTERNATOR 12 28 STATOR ALTERNATOR 12 29 BATTERY SERVICE 12 30 BATTERY SPECIFICATIONS GENERAL BATTERY INFORMATION 12 30 BATTERY REMOVAL INSTALLATION OFF SEASON STORAGE 12 30 BATTERY TESTING statt E 2 RR gn Seabee E SPURS URGE 12 30 OCV OPEN CIRCUIT VOLTAGE TEST LOAD TEST 12 31 BATTERY CONDUCTANCE ANALYZER 12 31 EXTREME USE 30 12 31 CHARGING 12 31 12 1 9923067 2011 850 Copyright 2010 Polaris Sales Inc ELECTRICAL STAR TER MO TOR gt STARTER STARTER LOCKOUT SYSTEM 12 32 TROUBLESHOOTING ene Sad eed Ap awa selene 12 32 VOLTAGE DROP 12 32 STARTER MOTOR REMOVAL REPLACEMENT 12 33 INSTRUMENT CLUSTER TROUBLESHOOTING INSTRUMENT CLUSTER KEY OFF 12 34 INSTRUMENT CLUSTER KEY ON POWER 12 35 INSTRUMENT CLUSTER NO HIGH BEAM INDICATOR
19. 2X4 TURF ADC 4X4 2X4 TURF 1 00 CAVITY FOR 850 50 CAVITY FOR 550 42 Pr E S 2 POWER IN PIN RO 06 T B aac V OUT PIN WH X O GN RD a COMMON PIN SPEED SENSOR LOCATED TRANSMISSION 12 49 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL ts ircui Light C HY JHOMT WL H1 8 2X 068 803 ALIAV
20. 850 TOUR INTL 7 6 SPEEDOMETER 12 52 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Cooling Fan and Electronic Power Steering Circuits COOLING FAN amp EPS EPS RELAY FAN EPS s us MOTOR POWER A gr GROUND B j Con 5 L TE EH CIRCUIT BN BREAKER BN 2 9 THN FUSE LINK 1 nca al SPLICE 06 6 53 d cac BN GROUND A DN a c 00 S NEHME BATTERY POWER 1 30 R S Bi EN 5 06 spee O6 KEY OW 1 6 100 2 102 5 EL 58 q GROUND VT RD WH HB7 Bi RELAY lt gt ECM SIGNAL GROUND SPLICE 06 5 CAVIT
21. HR Rate 310 Circuit Voltage 12 8 Vdc or more Recommended Charging Rate 1 8A 5 10 HR General Battery Information A WARNING CALIFORNIA PROPOSITION 65 WARNING Batteries battery posts terminals and related accessories contain lead and lead compounds and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm WASH HANDS AFTER HANDLING Serious bu Eyes Flush or using in A WARNING Battery electrolyte is poisonous It contains acid rns can result from contact with the skin eyes or clothing ANTIDOTE External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging closed space Always shield eyes when working near batteries Keep out of reach of children 12 30 1 Check battery voltage with a volt ohm meter A fully charged battery should be 12 8 V or higher 2 If the voltage is below 12 6 V the battery will need to be recharged see Charging IMPORTANT Never attempt to add electrolyte or distilled water to a Maintenance Free battery Doing so will damage the case and
22. Immediately clean off any gasoline that splashes on the instrument cluster 12 4 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Rider Information Display The rider information display is located in the instrument cluster All segments will light up for 1 second at start up NOTE If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer 1 RPM Vehicle Speed Display LCD display of either engine RPM or vehicle speed in MPH or km h 2 Information Area Service Odometer Engine Hours Trip Meter Display LCD display of the service hour interval total vehicle miles or km total engine hours and two separate trip meters 3 MPH km h Display MPH is displayed when the instrument cluster is in the Standard mode Km h is displayed when the instrument cluster is in the Metric mode 4 High Beam Indicator LED and LCD icon illuminate whenever the LH control headlamp switch is in the high beam position 5 Fuel Level Indicator LCD bar graph indicating current fuel level All segments will flash when the last segment is cleared indicating a low fuel warning 6 Clock Displays current time in either 12 hour or 24 hour formats 7 Engine Temperature Indicator LED and LCD icons illuminate when the ECM determines the engine is overheating The indicato
23. KM H is displayed when the instrument cluster is in the Metric mode 4 High Beam Indicator LED icon illuminates whenever the LH control headlamp switch is in the high beam position 5 Fuel Level Indicator LCD bar graph indicating current fuel level All segments will flash when the last segment is cleared indicating a low fuel warning 6 Clock Displays current time in either 12 hour or 24 hour formats 7 Engine Temperature Indicator LED icon illuminates when the ECM determines the engine is overheating The indicators will initially flash to indicate the engine is overheating The indicators will stay lit and not flash if a severe overheating condition exists 8 Service Interval Indicator Preset at the factory and adjustable by the user a flashing wrench symbol alerts the operator that the preset service interval has been reached and maintenance should be performed The wrench icon will flash for 10 seconds upon start up once it reaches 0 9 Check Engine MIL Illuminated when the ECM has detected a Diagnostic Trouble Code in the engine management system 10 AWD Indicator Illuminated when the RH control switch is in either 4x4 or ADC 4x4 position 11 TURF Indicator Illuminated when the RH control switch is in the TURF position X2 Models Only 12 Neutral Gear Indicator LED icon illuminates when gear selector is in the neutral N position 13 Gear Position Indicator Displays gear selector positio
24. SENSOR o gt gt NL lt s c e3 SPEEDOMETER OO ELECTRICAL Key On Power Circuits Int Models INTERNATIONAL POWER CIRCUITS POWERED DIRECTLY BY THE KEY SWITCH AND RUN STOP SWITCH THIS CIRCUIT SHOULD BE NEAR BATTERY M pee gewmow VOLTAGE WHEN THE BATTERY 15 CONNECTED gt z FRD BK Hi YEIDG LOCATED BELOW HANDLEBARS DIAGNOSTIC UA 2 R S B SPLICE THESE CIRCUITS SHOULD ALL BE NEAR BATTERY VOLTAGE WHEN THE KEY RU Rueda Fo
25. Vdc per connection 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Starter Motor Removal Replacement IMPORTANT The starter motor and solenoid can not be serviced Removing the black protective coating from the components will allow for premature component failure Replace the starter motor and solenoid as an assembly 1 Remove the seat and the upper and lower LH side panels 2 Disconnect the battery negative cable 3 Clean the area around the starter motor 4 Using 8 mm allen socket with an extension remove the 2 bolts retaining the starter motor Remove dipstick to allow for starter motor removal 5 Remove the engine oil dipstick to allow for starter motor removal 6 Remove the starter motor from the crankcase housing Reinstall the engine oil dipstick 7 Remove the key switch energize wire and battery cable from the starter solenoid Remove the starter motor assembly from the chassis Install the new starter motor assembly by reversing this procedure Be sure to install new O rings on the starter motor bell housing NEW O Rings 20 ft Ibs 27 Nm Starter Motor Mounting Bolts 20 ft Ibs 27 Nm 12 33 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL INSTRUMENT CLUSTER TROUBLESHOOTING The following 4 diagnostic tests can be performed without using Digital Wr
26. engine running Follow the steps below as outlined to reduce the chance of damage to electrical components 1 Verify the battery is fully charged and in good condition 2 With the engine running connect the multimeter to the positive and negative battery terminals 3 Test for with the multimeter 4 The meter display should read approximately 14 0 14 4 Vdc at idle 5 If the voltage is lower than 14 0 14 4 Vdc the alternator should be tested Stator Alternator Tests Three tests can be performed using a multimeter to determine the condition of the stator alternator a 12 27 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL TEST 1 Resistance Value of Each Stator Leg 1 Measure the resistance value of each of the three stator legs Connect Meter Test Leads To Ohms Reading Charge Coil Y1to Y2 Pin to 0 190 15 Charge Coil Y1to Pin Ato 10 190 15 Charge Coil Y2 to Pin Ato B 0 190 15 NOTE If there are any significant variations in ohm readings between the three legs one of the three stator legs may be weak or failed TEST 2 Resistance Value of Each Stator Leg to Ground 1 Measure the resistance value of each of the stator legs to ground Connect Meter Test Leads To Ohms Reading Battery Ch
27. transmission Remove the wiring harness connector and insert the The Electronic Throttle Control ETC switch is designed to close during throttle movement in the event the throttle cable sticks or breaks When the throttle lever is at idle position the ETC switch contacts should be closed touching When the throttle lever is moved the contacts will open and allow normal operation If the contacts remain closed or become closed during throttle movement the ECM will limit engine RPM Contacts are closed when throttle lever is at rest idle Signal ECU Ground RI ETC 2 1548 Q SWITCH multimeter probes into the switch 2 Move the gear selector handle to each of the 5 drive positions HIGH LOW NEUTRAL REV or PARK 3 Test for continuity between the switch contacts and connector leads Replace the switch if no continuity or high resistance is found in any of the gear positions Gear Selector Switch Testing A B D E F HIGH LOW NEU PARK _ _ Resistor Module Function Test The resistor module relays a different resistance reading to the ECM depending on which gear is selected by the operator If the module fails the ECM will not be able to determine what gear the transmission is in NOTE Reference Chapter 3 EFI for pin locations 1 Di
28. 2 COOLING FAN AND ELECTRONIC POWER STEERING CIRCUITS 12 53 CONTROLLER AREA NETWORK 12 2 9923067 2011 850 Copyright 2010 Polaris Sales Inc ELECTRICAL GENERAL INFORMATION Diagnostic Connector Special Tools Battery under rack PART NUMBER TOOL DESCRIPTION Fusee Relays PV 43568 Fluke 77 Digital Multimeter under side panel PA 49466 Test Relay PV 43526 Connector Test Kit Electrical Service Notes Keep the following notes in mind when diagnosing an electrical problem Refer to wiring diagram for stator and electrical component resistance specifications When measuring resistance of a component that has a low resistance value under 10 Ohms remember to subtract meter lead resistance from the reading Connect the leads together and record the resistance Q Brake Switch The resistance of the component is equal to tested value in master cylinder minus the lead resistance Wheel Speed Sensor Start Solenoid Regulator under side panel Rectifier under rack Become familiar with the operation of your meter Be sure leads are in the proper jack for the test being performed i e 10A jack for current readings Refer to the Owner s Manual included with your meter Voltage amperage and resistance values included in this man
29. BRAKE DIODE GROUND A BRAKE SWITCH u al YE HOH gy SRN LEFT HANDLEBAR SWITCH ASSY E SLE BN P N 4012435 Cr a 1 A YE DG H BN 4 T gt 8 BU RD J DB RD t pem z B c G e TALLIGHT Bag MOS MEN m SPLICE 6 6 P YE 5 mec 000 000 m NET L GROUND B JIKILIMINIP 5 amp TET CAVITY FOR 550 EPS INTL 20 LOW BEAM JO CAVITY FOR 550 TOUR INTL 8 FLASH PASS CAVITY FOR 550 X2 INTL 8 mE CAVITY FOR 850 EPS INTL 20 m 3 R TURN O1O Lo REV OVERRIDE CAVITY FOR 850 TOUR INTL 8 Loyp HAZARD LICENSE HORN O un B u SPEEDOMETER LH TAILLIGHT RH TAILLIGHT TM 12 51 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Turn Signals Hazard Lights IntI Models TURN HAZARD HAZARD FLASHER JEH 20100813 1 BATTERY
30. ECTRICAL Engine Start Command and Gear Switch Circuits Int Models 850 INTERNATIONAL ENGINE CRANK amp GEAR SENSE JEH 20100707 RD BN 4 gt IGNITION SWITCH FAN CIRCUIT BU YE m gt A oe Ba wH RD gt START 2 E SOLENOID gt NS 805 189 dm Q START SOLENOID GROUND START DIODE WH s DN WH RD 0G EX 06 BRAKE DIODE FAN RELAY LIGHTS B A o 9 PARK RD BN SPLICE O REV i lt 4 CHASSIS POWER 5 aji 12 LO l BRAKE SWITCH E 6 0 LOW CLOSED WITH HAND Ge
31. ELECTRICAL CHAPTER 12 ELECTRICAL GENERAL 5542 3X E ES 12 3 SPECIAL TOOLS ELECTRICAL SERVICE NOTES 12 3 COMPONENT 6 1 41 12 3 INSTRUMENT CLUSTER EPS 5 12 4 RIDER INFORMATION DISPLAY 12 5 SPEED 1 12 6 INFORMATION DISPLAY 12 6 DIAGNOSTIC uuu un dats ERU ARE UR REN RI 12 8 INSTRUMENT CLUSTER 12 9 INSTRUMENT CLUSTER XP X2 TOURING MODELS 12 10 RIDER INFORMATION DISPLAY 12 11 INFORMATION DISPLAY 12 12 DIAGNOSTIC MODE 1 12 14 INSTRUMENT CLUSTER 12 15 BRAKE SWITCH sacos ce a a s ya Summa 12 15 Is dose to date dpt as eO 12 15 ADCIAXA 2X4 T TUBE SWITCH oce vis veter pa E 12 16 uie MET c 12 16 REVERSE OVERRIDE MODE BUTTON 12 17 HEAD LAMP SWITCH
32. F 3 j t3 J irj sng sng o as os 2 S1H9I1 3 u3MOd zg 08 30765 HOLMS E 39148 49 03 Ev 515012 AY144 SISSVHO 81004 135 01 01 34V HOLIMS dOLS NNY JHL NAY NV HOLIMS AIM JHL 5114 AU311V8 335 Q3123NNOO 1 4431199 3Hl 0481004 38 S11028129 35361 3MOd SISSVH9 2154 00 10100102 9923067 2011 850 Copyright 2010 Polaris Sales Inc 12 46 ELECTRICAL Chassis Power Circuits Int Models HEH 20100107 INTERNATIONAL CHASSIS POWER THESE CIRCUITS WILL BE POWERED WHEN THE BATTERY 15 CONNECTED SEE BATTERY PLUS 2 THE KEY SWITCH AND RUN THE RUN STOP SWITCH ARE CLOSED SEE KEY ON POWER 3 THE CHASSIS RELAY CLOSES
33. HIGH BRAKE APPLIED GEAR SELECTOR SWITCH RESISTOR MODULE LOCATED AT LEFT RESISTANCE 5 U HAND CONTROL LOCATED BELOW HEAD LAMP A lt 06 300 OHM E SPLICE SPEEDOMETER CAVITY FOR 850 EPS INTL 4 5 eds CAVITY FOR 850 TOUR INTL 2 CAN HIGH SPLICE YE CAN LOW RE SPLICE GN c THE ECM WILL ALLOW CRANK CONNECT PIN 10 WIRE E70 TO GROUND IF THE TRANSMISSION IS IN 33 64 10 8 10 A PARK OR B NEUTRAL OR ECM 2 THE BRAKE SWITCH 15 ACTIVATED AND 3 THE ENGINE 1S NOT RUNNING 12 45 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL
34. Instrument Cluster Incorrect Fuel Level No or erratic fuel level instrument gauge 754 Determine cause 15 Battery Fully NO of incorrect battery Charged voltage and repair 5 si L Test fuel level signal at Z gt instrument cluster wiring harness THE Empty 90 4 50 1200000 0 000006 0 a Full 6 10 0800000000002 Pins 2 and 23 26 oe Pins 2 and 11 16 Pin Connector 4 Fuel level signal j NO Troubleshoot fuel pump and fuel found at harness pump level signal VT WH circuit Replace instrument cluster 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc 12 37 ELECTRICAL ELECTRONIC POWER STEERING EPS EPS Operation The EPS module is an intelligent electronic power steering system that operates off of the vehicle s 12V electrical system It calculates steering assist by sensing the difference between the input torque of the steering post and the output torque required to turn the wheels and then provides assist by energizing an electric motor The process provides a smooth seamless assist The system is continuously running diagnostic checks and monitoring factors such as battery voltage ground speed and engine speed In the event an internal or external issue that affects the EPS system is d
35. O 0 f 72 8 801 068 x 0 E OZ 43 068 404 ALIAVO 0 0 8 dX 058 ALIAVO 0 30 MW 340 8 ZX 066 ALIAVO Fac 9 UNOL OGG ALIAYO E D o et 43 066 803 8 125 4X 066 801 0 gt T L aa Sy _ T FT u amp 440 Ng B 302 01 4 m 39745 1 im 39s IHON 004 B i Mol In 8 LHOITIVL J 7 907317 4 3 8 j di pres ATANISSY HOLIMS 8 T YVESIONVH 1497 NO 19 F 30010 1H9n 90 555 CE 34 3aoid 90 90 dd duh 90 2 22 1 HOLIMS GE 066 03 4 ALIAYD 7 79 058 04 amp ALIAVO 5216 I N9 e QNnouo ee X08 3JMVINI IL i jer guy 8 v em peu 9 Y tp AV Eu 216 SLHOM u3dAna 48 SHON NG 74 g L voz E T 90 Tipe 90 97 LJ Sng 90 u3MOd SISSYHO shE 51 9 JILS3WOQ 10100102 12 50 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Light Circuits Models JEH 20100707 INTERNATIONAL LIGHTS
36. OTE The power steering relay is not located inside the fuse box The power steering relay provides power to the following system Power Steering Drive Motor Power Steering Relay Color Function LH RUN switch supplied 12 Vdc OBS eae battery voltage to relay coil BRN Relay coil ground ORG 87 b Power steering 12 Vdc battery power 30A fuse protected 12 Vdc battery voltage RD Rear Differential Solenoid Relay X2 Models NOTE The rear diff solenoid relay is not located inside the fuse box The rear differential solenoid relay provides power to the following system Rear Differential Solenoid Rear Differential Solenoid Relay Color Function Relay switched voltage to rear diff HD pin Relay switched ground for rear diff Beep solenoid RD 3 Key switched 12 Vdc battery power 3 pin ECM relay control circuit for relay coil BRN 3 Ground for relay coil 12 23 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL FUSES Protected Circuits Fuse Table Fuse Protected Circuits 10A Circuit Fan Motor Preaker Starter Solenoid Not Fuse EFI Relay controlled circuits 20A EFI Ignition coil pack Fuel Pump Fuel Injectors ECM 10A Unswitched Fan Relay Driver Power Ignition Switch Instrument Cluster 30A EPS Power S
37. Standard 12 hour Metric 24 hour To set the clock follow these steps 1 2 Toggle MODE button until the odometer is displayed Press and hold the MODE button until the hour segment flashes Release the button With the segment flashing tap the MODE button to advance to the desired setting Press and hold the MODE button until the next segment flashes Release the button Repeat steps 3 4 twice to set the 10 minute and minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode Units of Measurement Standard Display Metric Display Distance Miles MPH Kilometers KM H Time 12 Hour Clock 24 Hour Clock To change between Standard and Metric units of measurement follow these steps 1 2 Turn the key to the OFF position Press and hold the MODE button while turning the key to the ON position When the display flashes the distance setting tap the MODE button to advance to the desired setting Press and hold the MODE button to save the setting and advance to the next display option Repeat the procedure to change remaining display settings 12 13 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery ch
38. Y FOR 550 39 46 19 4 48 34 SIGNAL CAVITY FOR 850 36 33 Il 11 26 co RO id YE GN ECM LOCATED ON LEFT SIDE OF AIR INTAKE BOX CAN HIGH CAN LOW SPLICE SPLICE Lo gt 12 53 9923067 2011 850 Copyright 2010 Polaris Sales Inc ELECTRICAL CONTROLLER AREA NETWORK CAN Overview This vehicle uses a Controller Area Network CAN to perform some functions Similar to a computer network CAN establishes a communication network between the ECM and several on board components The CAN network includes ECM Instrument Cluster Digital Wrench Diagnostic Plug Electronic Power Steering EPS models only NOTE DO NOT SPLICE OR CUT INTO THE CAN YELLOW OR GREEN WIRE CIRCUITS CAN Troubleshooting No CAN functionality can be indicated by the following items not working on the instrument cluster No engine speed displayed No vehicle speed displayed No gear position displayed Odometer Tripmeters not working Reverse override button does not toggle between display modes ECM monitored inputs are not displayed when DTCs or problems exist i e check engine LED engine overheat LED etc There is power at the Smart Link connector but it cannot connect to Digital W
39. arge Y1 Y2 or Open Line Coil to Ground Infinity NOTE Any measurement other than Infinity open will indicate a failed or shorted stator leg TEST 3 Measure AC Voltage Output of Each Stator Leg at Charging RPM 1 Set your multimeter meter to measure AC Voltage 2 Disconnect the 3 wire stator connector near the stator housing 3 Start the engine and let it idle 4 While holding the engine at a specified RPM separately measure the voltage across each leg of the stator by connecting the meter leads to the wires leading from the stator Y1 to Y2 Y1 to Y3 Y2 to Y3 5 Refer to the following table for approximate AC Voltage readings according to RPM Test each leg at the specified RPM in the table NOTE If one or more of the stator leg output AC voltage varies significantly from the specified value the stator may need to be replaced RPM Reading AC Voltage Reading 115 Vac 10 Nominal 6000 17 Vac 10 Peak 12 28 Stator Alternator Removal 1 Remove the fuel tank see Chapter 3 2 Remove the 4 screws retaining the engine skid plate and remove the plate from the vehicle 3 Place a drain pan under the front portion of the engine 4 Remove the coolant hose from the water pump housing Inlet Hose e 5 Slowly drain the coolant into the drain pan Dispose of used coolant properly 6 Disconnect the stator and CPS w
40. arged It may also occur when the engine is at idle and a high electrical load is applied lights cooling fan or other accessories If battery voltage drops below 11 volts a warning screen will display Lo and provide the present battery voltage If voltage drops below 8 5 volts LCD backlighting and icons will turn off If battery voltage rises above 15 volts a warning screen will display OV and provide the present battery voltage If voltage rises above 16 5 volts LCD backlighting and icons will turn off Diagnostic Mode The diagnostic mode is accessible only when the check engine MIL has been activated NOTE If there is a diagnostic problem with the power steering system the power steering MIL will illuminate and blink in place of the check engine MIL Use the following procedure to display diagnostic trouble codes that were activated during current ignition cycle causing the MIL to illuminate Diagnostic trouble codes will remain stored in the gauge even if MIL turns off until the key is turned off 12 14 If the trouble code s are not displayed use the MODE button to toggle until ENG displays on the information display area Press and hold the MODE button to enter the diagnostics code menu A set of three numbers will appear in the information display area The first number located far left can range from 0 to 9 This numb
41. ast 1 2 hours after being properly charged If the voltage drops below 12 6 volts charging was ineffective or the battery needs to be replaced A WARNING An overheated battery could explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Battery PN 4011496 State of Charge Charge Voltage DC Action Time None check None 100 12 8 13 0 again in 3 Required months 75 100 12 5 12 8 MA IEEE sal slight charge 50 75 12 0 12 5 Needs Charge 5 11 hrs At least 25 50 11 5 12 0 Needs Charge 13 hrs At least 0 25 11 5 or less Needs Charge 20 hrs NOTE Follow the charger instructions supplied by the manufacture regarding the order or connections switch positions and when to connect the charger to an outlet STARTER MOTOR Starter Starter Lockout System Diagram The starter and starter lockout system consists of Battery Fuse or Circuit Breaker Key Switch Off Run Switch Starter Solenoid Brake Switch Transmission Neutral Switch Start Diode Starter Motor 12 32 Troubleshooting Starter Motor Does Not Run Battery discharged Loose or faulty battery cables or corroded connections see Voltage Drop Tests Related wiring loose disconnected or corroded Poor ground connections at ba
42. ch if function does not pass test Pin 2 Brakes Not Applied Brakes Applied IGNITION SWITCH Function Test Use a multimeter to test for continuity between the 3 sets of ignition switch outputs OFF ON START If any of the tests fail replace ignition switch assembly Ignition Switch Test OFF x O 6 START O O Q O Turn the ignition key to ON There should be continuity between pins and D A and Turn the ignition key to START There should be continuity between pins A and B C and D Function Test INT L Use a multimeter to test for continuity between the 4 sets of ignition switch outputs OFF ON LIGHTS START If any of the tests fail replace ignition switch assembly Ignition Switch Test INT L OFF LIGHTS ON 065 00 sr O O 9 0 Q O Turn the ignition key to ON LIGHTS There should be continuity between pins A E and F C and D Turn the ignition key to ON There should be continuity between pins C and D E and F Turn the ignition key to START There should be continuity between pins A and B C and D E and F Ignition Switch Connector View 12 15 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL ADC 4X4 2X4 TURF SWITCH Function Test Use a multimeter to t
43. ctor Troubleshoot BRN 4 1 ground and Bata votiage NO ORANGE ignition harness and run switch power circuits YES Replace instrument cluster f F 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc 12 35 ELECTRICAL Instrument Cluster No High Beam Indicator high beam indicator on instrument panel when high beam lamp activated Determine cause Z Battery Fully NO of incorrect battery S Charged p voltage and repair k gt UN YES gt gt LIGHTS 20A fuse gt OK 2 NO Replace fuse ES b p F YES Move key switch to ON LH switch to RUN and headlamp switch to HIGH f ed 1 f Test for battery voltage at dut instrument cluster wiring harness 2 Pins 2 and 20 24 Pin Connector 24000 oe 00006 Pins 5 and 8 16 Pin Connector VE f W 4 A E Troubleshoot BRN gt round and d Battery voltage at 3 NO oon high lt 2 gt p beam voltage Pp circuits b D YES Replace instrument cluster 12 36 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL
44. d be continuity between pins B and C FREE PUSH Reverse Override Mode Button Test INT L BN GY OG HEAD LAMP SWITCH Function Test Use a multimeter to test for continuity between the head lamp outputs in the LH control assembly If any of the tests fail replace the LH control assembly Headlamp Switch Test D E F OFF LOW HIGH There should be no continuity when the switch OFF Move the switch to LOW There should be continuity between pins D and F Move the switch to HIGH There should be continuity between pins D and E Dimmer Switch Test FREE PUSH Q U YE DG 0 0 LOW Push the Reverse Override Mode button There should be continuity between pins M BN and E 0800 HIGH Move the switch to LOW There should be continuity between pins YE DG and DG Move the switch to HIGH There should be continuity between pins YE and YE DG 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL ELECTRONIC THROTTLE CONTROL ETC SWITCH Electronic Throttle Control ETC Switch GEAR SELECTOR SWITCH Selector Switch Function Test 1 Locate the gear selector switch on the
45. ea Information displayed in this area includes Odometer Trip 1 Trip 2 engine hours service interval engine Diagnostic Trouble Codes DTCs and power steering DTCs 1 Press and release the SELECT button on the instrument cluster or press and release the LH control REVERSE OVERRIDE button to toggle between the information displays NOTE DTC display modes can only be accessed using the SELECT button on the instrument cluster Select button on instrument cluster is locked out when vehicle speed is above 15 MPH 12 6 Odometer The trip meters record the miles traveled by the ATV on each trip To reset a particular trip meter 1 Toggle the SELECT button to either TRIP 1 or TRIP 2 2 To reset to 0 push and hold the MODE button until the distance display changes to 0 Engine Hours 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Engine hours are logged anytime the engine is running Total hours can not be reset Programmed Service Interval The initial factory service interval setting is 50 hours Each time the engine is started the engine hours are subtracted from the service interval hours When the service interval reaches 0 the LCD wrench icon will illuminate for approximately 10 seconds each time the engine is started To change the hour setting or reset the function follow these steps 1 Toggle the SELECT button until SRV is displayed in the
46. ed If the connector is not installed correctly the Power Steering Unit will not function This situation can be avoided by paying close attention when installing the 8 way connector If the 8 way is connected properly the vehicle should have assist with the key on Wire Color Functions Wire Color Function Key On Run Switch On Battery ORANGE Voltage EPS Power RED Battery Voltage BROWN Ground YELLOW CAN High Signal GREEN CAN Low Signal Proper EPS System Diagnosing READ BEFORE YOU REPLACE THE EPS UNIT IMPORTANT Try to reflash the EPS unit before attempting to replace it A simple reflash may be all that is needed to repair the EPS problem Always reflash the EPS unit as the first step in diagnosing an EPS problem EPS Circuit NOTE Refer to Cooling Fan amp EPS breakout diagram near the end of this Chapter 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL EPS Troubleshooting Power Steering Non Functional MIL is ON Determine cause of incorrect battery voltage and repair Is Battery Fully Charged Yes 13 EPS Fuse OK No Replace EFS Fuse Yes 12 and GND across the 2 Pin EPS Connector with Key On Check EPS No Power Relay and Circuit Yes Check wiring from Connector to No Ignition switch Check Ignition Switch Circuit 12 Vdc on Pin 3 of the 8 pin EPS Connector Yes Begin Di
47. ench Troubleshooting functions not listed here can be found using Digital Wrench Guided Diagnostics Instrument Cluster Key OFF No Power No power at instrument cluster 4 SN Determine cause Is Battery Fully N of incorrect battery Charged D voltage and repair 5 s un switched 10A gt fuse OK gt NO Replace fuse 5 f 1 Test for battery voltage at 2 SN instrument cluster wiring harness 2000000000 Pins 1 2 24 Pin Connector 0000000000 9 Pins 4 and 5 16 Pin Connector E Tu Troubleshoot BRN ground and RED 4 Battery voltage at gt N N harness p WHT battery S p voltage circuits Replace instrument cluster 12 34 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Instrument Cluster Key ON No Power No power when key switch and run switch Determine cause of incorrect battery NO 34 voltage and repair Is Battery Fully gt Charged YES g un switched 10A 1 fuse OK NO Replace fuse YES 1 r1 Test battery voltage at TEE instrument cluster wiring harness 2000000000 00909 2 3 24 Pe lt Pins 3 and 5 16 Pin Conne
48. er represents the total number of trouble code present example 2 means there are 3 codes present The second number located top right can be 2 to 6 digits in length This number equates to the suspected area of fault SPN The third number located bottom right can be to 2 digits in length This number equates to the fault mode SPN Suspect Parameter Number Error Code Number 0 9 FMI Failure Mode Identifier Use the trouble code reference table in the EFI Chapter for a description of each code If more than one code exists press the MODE button to advance to the next trouble code To exit the diagnostic mode press and hold the MODE button or turn the ignition key OFF once the codes are recorded 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Instrument Cluster Pinouts AT 2 FUNCTION PIN CAN High 1 CAN Low 2 Switched Power Vdc 3 Constant Power Vdc 4 Ground 5 High Beam Input 8 Fuel Level Sensor 11 International Models Only Turn Signal Input LH 6 Turn Signal Input RH 7 BRAKE SWITCH Function Test Applying the brakes closes a switch to activate the brake lamps Use a multimeter to test for continuity when the brakes are applied Brake Switch Test Pin 1 Replace the brake swit
49. er the CHASSIS relay is active The circuit is also protected by the 20A DRIVE fuse The ECM controls all ADC and AWD functions Diagnosing System Failures ADC COIL i20 ex B Han GY e Verify the ADC AWD switch is functional and that a minimum of 11 volts is present at the hub coil connection e Verify the ADC AWD hub coil is functional Test the AWD hub coil using a multimeter Verify the wiring harness wiring connectors connector pins and grounds are undamaged clean and connected properly Verify continuity of wire connections with a known good volt ohm meter Verify the coil wires are not connected or shorted to ground IMPORTANT Verify all wires and wiring connections have been tested properly with a known good volt ohm meter before suspecting a component failure 80 of all electrical issues are caused by bad connections and or grounds AWD ADC Function Tests The following diagnostic test can be performed before using Digital Wrench Troubleshooting functions not listed here can be found using Digital Wrench Guided Diagnostics NOADC AWD b 4 Battery Fully N Determine cause gt of incorrect battery Charged voltage and repair YES DRIVE 20A Fuse DNO Replace fuse YES Troubleshoot the Chassis Relay NO Fuse Box LH and Key switch components t
50. ery will have at least 10 5 volts If the reading is low charge the battery and retest Battery Conductance Analyzer Conductance describes the ability of a battery to conduct current A conductance tester functions by sending a low frequency AC signal through the battery and a portion of the current response is captured from this output a conductance measurement is calculated Conductance testing is more accurate than voltage specific gravity or load testing Authorized Polaris dealers distributors are required to use the conductance analyzer when testing 12V Polaris batteries Polaris MDX 610P Conductance Analyzer Polaris MDX 610P SPX PN PU 50296 Extreme Use 30 AH Battery Polaris offers an optional 30 AH battery PN 4011224 for use in extreme conditions where the factory installed battery can not maintain a charge because of multiple electrical accessories Charging Procedure If battery voltage is 12 6 Vdc or less the battery may need recharging When using an automatic charger refer to the charger manufacturer s instructions for recharging Do not exceed 9 amps when charging the 4011496 battery NOTE Charge the battery using an automatic charger that will not exceed 14 6 Vdc An automatic charger will signal when charging is complete 12 31 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL NOTE Allow the battery to stand disconnected for at le
51. est for continuity between the two switch outputs ADC AWD If testing an X2 model test for continuity between the three switch outputs ADC AWD TURF NOTE Selecting 2x4 drive mode does not complete any circuits All circuits should be OL when 2x4 is selected ADC 4 4 2x4 TURF Switch Test 3 4 5 ADC 4x4 4 4 2 4 TURF Move the drive selector switch to each drive mode and then test for continuity If any of the tests fail replace the RH throttle switch assembly 12 16 OFF RUN LH SWITCH Function Test Use a multimeter to test for continuity when the LH switch is moved to the RUN position If the test fails replace the LH control assembly Move the switch to the RUN position and test Off Run Switch Test F Left Connector C Right Connector OFF L3 Run Switch Test RD BK OR OFF RUN 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL REVERSE OVERRIDE BUTTON Function Test Use a multimeter to test for continuity when pressing the Reverse Override Mode button If the test fails replace the LH control assembly Reverse Override Mode Button Test B Push the Reverse Override Mode button There shoul
52. etected the system will illuminate a fault indicator and transition to a normal mechanically coupled steering system The system is Polaris Digital Wrench compatible for simplified diagnostics and system troubleshooting through the vehicle s diagnostic port With the engine off and the key on the power steering unit will operate for up to five minutes After the five minutes you will need to either cycle the key switch or start the engine to regain power steering operation The Power Steering 30A Fuse If the fuse fails the Power Steering Malfunction Indicator Light MIL on the instrument cluster will illuminate During this time the vehicle will have no power steering operation You will be able to connect and communicate with the vehicle s Engine Controller but not the Power Steering Controller while using Digital Wrench NOTE DO NOT SPLICE OR CUT INTO THE CAN CIRCUITS A WARNING Electronic Power Steering EPS units are not interchangeable between ATV and RANGER product lines NOTE Refer to Chapter 10 Steering Suspension for power steering unit removal and installation procedures 12 38 EPS 8 Way Wire Harness Connector The 8 way connector two rows of four pins does not have a channeled lock on both sides allowing it to be installed 180 from its intended position The connector will not positively engage or snap into place while in the wrong position but can still be install
53. gital Wrench EPS Troubleshooting Procedure 12 39 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL ELECTRICAL BREAKOUT DIAGRAMS Battery Charging Circuits JEH 20100707 BATTERY CHARGING VOLTAGE REGULATOR LOCATED IN FRONT OF RADIATOR 5 s CHARGE COIL YEI TO YE2 0 130415 Sar CHARGE COIL YEI TO YE3 0 130155 CHARGE COIL YE3 YE2 0 130415 YE3 TO GROUND OPEN x YE STATOR BATTERY PLUS RY Ot 12 40 9923067 2011 850 Copyright 2010 Polaris Sales Inc ELECTRICAL Constant Power Circuits 850 BATTERY PLUS JEH 20100707 CIRCUITS POWERED DIRECTLY BY THE BATTERY SPEEDOMETER CAVITY FOR 850 XP 4 giis CAVITY FOR 850 EPS T RD CAVITY amp FOR 850 TOUR 4 CIRCUIT CHASSIS CAVITY FOR 850 X2 4 BREAKER RELAY CAVITY FOR 850 EPS INTL UNSWITCHED FUSE SPLICE CAVITY FOR 850 TOUR INTL 4 gt THESE CIRCUITS ARE AFTER THE REVERSE POLARITY DIODE AND
54. gits in length This number equates to the 1 With the ignition key in the OFF position press and hold suspected area of fault the MODE button 2 While still pressing the MODE button turn the ignition key to the ON position Continue holding the MODE button until the time begins to flash 3 Follow steps 3 5 in METHOD 1 to set the clock Units of Measurement 5 The second number will appear in the clock area and can 1 to 2 digits in length This number equates to the fault mode To change between Standard and Metric units of measurement follow these steps 1 Toggle the MODE button until the vehicle speed is displayed on the screen 2 Toggle the SELECT button until the odometer is displayed in the information area 3 Press and hold the MODE button until the units of measurement in the speedometer area change MPH to km h or km h to MPH 6 Use the trouble code reference table in the EFI Chapter for a description of each code 7 Press and hold the MODE button to cycle through all 4 Release the button when the desired setting is achieved currently active codes units including vehicle speed and odometer trip meters will be set to the desired Standard or Metric units NOTE On vehicles equipped with power steering the power steering MIL LED will illuminate and blink Diagnostic Mode in place of the check engine MIL if there is a Use the following procedure to display diagnostic troub
55. he headlights or _ Z accessory power plugs N work when key and stop N switch are on 7 12 Vdc at Z ADC AWD Harness Pins D when key and stop lt switch are Is there gt continuity between pins ECU 63 N pins Band ECU Troubleshoot wiring harness N Pinge y YES X 2 Does the gt ADC coil Q 12 Q roubleshoot front and the gt A gearcase N coil Q 24 0 YES P A Use Digital Wrench Guided Diagnostics E 12 21 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL RELAYS Relay Overview Each relay leg or corner performs the same function Chassis Relay The chassis relay provides power to the following systems Head Lights Tail Lights Brake Light e AWD Coil ADC Coil RH Drive Switch Accessory Power Points Fan Relay The fan relay provides power to the following system Fan Motor Fan Relay Color Function RD WHT 10A Circuit breaker protected 12 Vdc battery voltage ORG YEL ECM control circuit for relay coil RD WHT Constant 12 Vdc battery voltage to relay coil ORG BLK Fan motor power 12 Vdc EFI Relay The EFI relay provides power to the following system Ignition Coil Power Fuel Pump Power Fuel Injector Power
56. ire harnesses 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL 7 Remove the coolant by pass hose from the water pump 3 Torque the stator and wire guide bolts to specification cover fitting 8 Remove the 8 screws retaining the stator cover 4 Install new O rings on the coolant pipe and lightly lubricate 9 Carefully remove the stator cover taking care not to damage for ease of installation the plastic coolant pipe CAUTION Lubricate The flywheel contains powerful magnets Use caution when removing and installing the stator cover DO NOT place fingers between cover and crankcase at any time during the removal installation process or injury could result 10 Remove the CPS stator wire guide and stator from the Coolant Pipe 5 Torque the 8 stator cover bolts to specification using the torque sequence provided Stator Cover Torque Sequence Stator Alternator Installation 1 Reverse the Stator Alternator Removal procedure to i Torque screws to reinstall the stator 89 in Ibs 10 Nm 2 Use the following steps to ensure proper assembly 12 29 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL BATTERY SERVICE Battery Specifications Battery PN 4011496 Polaris Yuasa YTX20HL BS Type Sealed Maintenance Free Voltage 12 Nominal Capacity 10
57. is receiving 12 volts and that a ground path is present 1 2 3 Disconnect the headlight lamp from the wiring harness sure to pull on the connector not on the wiring Turn the lamp counterclockwise to remove it Insert new the new lamp and turn it clockwise to secure it Reinstall the wire harness to the lamp NOTE Make sure the tab on the lamp locates properly in the housing 12 26 Tail Brake Bulb Replacement Before replacing the bulb use a digital multimeter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present If a tail light or brake light does not work the bulb may need to be replaced Base TOURING Models 1 Remove bulb by turning the rubber base 1 4 turn and pulling the bulb out Replace it with recommended bulb Apply Dielectric Grease PN 2871329 to the connection 2 Test the tail light and brake light to verify it is working properly X2 Models 1 Open the tailgate and remove the two screws near the tailgate latch Remove Screws 2 Grasp the entire taillight assembly and pull it away from the vehicle Remove the harness connector from the back of the light assembly and turn the bulb 1 4 turn counterclockwise to remove it 3 Reinstall the bulb Apply dielectric grease to the electrical connection and reinstall the harness 4 Test the light for proper operation 5 Reinstall the taillight assembly and the two screws
58. le codes diagnostic problem with the power steering system loggedin the ECM if the check engine MIL is illuminated on the instrument cluster 1 Place the transmission in PARK 2 Push and release the SELECT button to toggle through the LCD display until the check engine MIL icon is flashing 3 When the check engine MIL icon is flashing a set of two numbers will appear on the LCD 12 8 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Instrument Cluster Pinouts OO O O O 2 NOTE Some functions not found all models NN 1 Hi Instrument Cluster Pinouts FUNCTION PIN Battery Voltage Vdc 1 Ground 2 Run Stop Switch 3 CAN High 4 CAN Low 5 High Beam Input 20 Fuel Level Sensor 23 International Models Only Hazard Warning 10 Left Turn Signal 21 Right Turn Signal 22 12 9 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL INSTRUMENT CLUSTER XP X2 TOURING MODELS Overview The instrument cluster displays critical vehicle information to the user Reference the following page for display functions and descriptions NOTE Some features not ap
59. n H High L Low N Neutral R Reverse P Park Gear Signal Error shifter stuck between gears 14 Power Steering System MIL LED icon illuminates when a fault has occurred with the power steering system This indicator illuminates when the key is turned to the ON position and goes off when the engine is started 15 Turn Signal Hazard Lamp Indicator LED icon illuminates whenever the LH RH or hazard lamps are activated International Models Only 16 Active Descent Control Indicator Illuminated when the RH control switch is in the ADC 4x4 position and ADC is active 12 11 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Information Display Area The LCD portion of the instrument cluster is the information display area Information displayed in this area includes odometer trip meters engine RPM engine hours service interval clock engine Diagnostic Trouble Codes DTCs and power steering DTCs The reverse override button on the LH control acts as the MODE button when pressed and released quickly The transmission cannot be in reverse when using the override button as a MODE button Odometer The odometer records and displays the total distance traveled by the ATV The odometer can not be reset Trip Meters Trip1 Trip 2 The trip meters records the miles traveled by the ATV on each trip T
60. o reset the trip meters 1 Toggle the MODE button to Trip 1 2 reset 0 push and hold the MODE button until the distance display changes to 0 3 Perform this same procedure to reset Trip 2 12 12 Tachometer RPM Engine RPM can be displayed digitally Engine Hours Engine hours are logged anytime the engine is running Total hours can not be reset Programmed Service Interval The initial factory service interval setting is 50 hours Each time the engine is started the engine hours are subtracted from the service interval hours When the service interval reaches 0 the LCD wrench icon will flash for approximately 10 seconds each time the key is turned ON 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL To change the hour setting or reset the function follow these steps 1 Toggle the MODE button until the wrench icon is displayed in the information area 2 Press and hold the MODE button until the information display area begins to flash 3 Toggle the MODE button to increase the service interval hours in 5 hour increments to a maximum of 100 hours 4 To turn off the service interval function toggle the MODE button until OFF is displayed Clock The clock displays the time in a 12 hour or 24 hour format Refer to Units of Measurement to change the format
61. or power from the relay connector to ensure the to Chapter 8 DIFFERENTIAL GEARCASE 2 for solenoid has power to be activated a mechanical operation overview Check the RH switch wires for loose connections Remove the solenoid from the rear differential and ensure the solenoid plunger is actuating RIGHT HANDLEBAR SWITCH ASSEMBLY Solenoid Differential Solenoid Circuit Operation The Rear Diff Solenoid Relay is located on the frame under the rear cargo box PE KEYON e When the RH switch is pushed to activate the TURF mode a POWER signalis provided to the ECM from the switch to power the Rear Diff Solenoid Relay 4x4 2 4 4 4 Depending on engine speed wheel speed and gear position criteria the ECM energizes the Rear Diff Solenoid Relay allowing it to enable the differential solenoid CAUTION If testing the differential solenoid directly do not power the solenoid with 12 Volts for more than 1 second or damage may occur to solenoid 12 20 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL AWD ADC COILS Operation Overview Battery voltage is always present at the AWD and ADC coils when the CHASSIS relay is active AWD and ADC coil voltage is protected by the 20 DRIVE fuse Battery voltage is always present at the ADC 4 4 2x4 RH switch assembly whenev
62. orming this procedure 4 Start the engine and turn the headlight switch to high beam 5 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed 2 in 5 cm below the mark placed on the wall in Step 3 6 Loosen the adjustment screw at the rear of the headlamp ADJUSTMENT SCREW 7 Adjust the beam to desired position and tighten the screw Due to the nature of ATVs and where they are operated A WARNING headlight lenses become dirty Frequent washing is necessary to maintain lighting quality Riding with poor lighting can result in severe injury or death Bumper Lamp Adjustment 1 Loosen the Phillips screw located at the rear of the lamp 2 Tilt the lamp upward or downward to the desired position and tighten the screw 3 Repeat the procedure to adjust the other bumper light to the same height 12 25 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Headlight Replacement 1 2 Remove the 4 side and 1 rear mounted pod screws Carefully remove the headlight lens from the pod Unplug the headlight from the harness and remove the bulb Install a new bulb and install the lens back into the pod Reinstall the mounting screws Bumper Lamp Replacement Before replacing the lamp use a digital multimeter to test the harness to ensure the lamp
63. plicable to all models IMPORTANT The use of a high pressure washer may damage the instrument cluster Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the instrument cluster lens Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster 12 10 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Rider Information Display The rider information display is located in the instrument cluster All segments will light up for 1 second at start up NOTE If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer The reverse override button on the LH control acts as the MODE button when pressed and released quickly The transmission cannot be in reverse when using the override button as a MODE button 1 Vehicle Speed Display Analog display of vehicle speed in MPH or km h 2 Information Display Area Odometer Trip Meter Tachometer Engine Hours Service Info Clock LCD display of the service hour interval total vehicle miles or km total engine hours trip meters and engine RPM 3 MPH KM H Display MPH is displayed when the instrument cluster is in the Standard mode
64. rench To test the CAN circuit turn the ignition key to OFF and then use a multimeter to verify there is 60 10 ohms between the CAN High YELLOW and CAN Low GREEN wires on the diagnostic connector If 120 ohms is measured at the connector there is a break somewhere within the CAN circuit 12 54 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc
65. rs will initially flash to indicate the engine is overheating The indicators will stay lit and not flash if a severe overheating condition exists 8 Service Interval Indicator Preset at the factory at 50 hours and adjustable by the user the icon will illuminate at engine start up for 10 seconds when the engine hours meet the hour threshold indicating when maintenance should be performed 9 Select Button Press and release to toggle through the information area fields The fields are Odometer Trip 1 Trip 2 engine hours and service interval The information area will also display any current Diagnostic Trouble Codes if applicable NOTE Select button locked out when vehicle speed is above 15 MPH 10 Battery Voltage Indicator LCD icon is displayed when the battery voltage is either too low less than 10V or too high greater than 16V as determined by the ECM 11 Check Engine MIL Illuminated when the ECM has detected a Diagnostic Trouble Code in the engine management system Icon will flash when DTC display mode is active 12 Mode Button Press and release to toggle between engine RPM or vehicle speed displays The mode button is also used to change units reset the trip meters enter clock set mode enter service interval update toggle through DTCs and display the clock with key out of ignition NOTE The mode button is locked out when vehicle speed is above 15 MPH 13 AWD Indicator Illuminated
66. sconnect the ECM harness connector from the ECM Locate pins 8 WHITE and 33 VIOLET Set the multimeter to register OHMS resistance Insert the RED probe into pin 8 and the BLACK probe into pin 33 Reference the Resistance Table for specifications If any of IMPORTANT The throttle cable must have the proper amount of free play adjustment Refer to Chapter 2 Throttle Cable Adjustment procedure Throttle Lever at Rest idle Normal Operation throttle open or above idle ETC Switch Contact Positions ETC is CLOSED Pins 1 and 2 2 15k ETC is OPEN Pins 1 and 2 Q 6 76k Throttle Cable Stuck ETC is CLOSED Pins 1 and 2 0 2 15k 12 18 the tests fail replace the resistor module Module Resistance 596 Gear Position OHMS HIGH 620 LOW 300 NEUTRAL 160 REVERSE 75 PARK 24 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL SPEED SENSOR Vehicle Speed Sensor The vehicle speed sensor is mated to the transmission housing and reads the speed of the transmission output gear Battery voltage is supplied to the sensor on the ORANGE circuit and is energized when the OFF RUN and ignition switches are in the RUN and ON positions To test the circuit 1 2 Turn the ignition key to the ON position and move the OFF RUN switch to RUN Verify there is battery vol
67. shorten the life of the battery To service a Maintenance Free battery 1 Remove battery from the vehicle see Chapter 2 2 Test battery with a voltage meter or load tester to determine battery condition This will determine the length of time required to charge the battery to full capacity Refer to OCV table see Open Circuit Voltage Test 3 Charge the battery as recommended see Charging Procedure Battery Removal Installation See Chapter 2 Maintenance for battery removal and installation procedures Battery Off Season Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge NOTE Battery charge can be maintained by using a Polaris battery tender charger or by charging once a month to make up for normal self discharge Battery tenders can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Testing Whenever a service complaint is related to either the starting or charging systems the battery should be checked first Following are two tests which can easily be made on a sealed Maintenance Free battery to determine its condition OCV Test and a Load Test 9923067
68. tage present on the ORANGE circuit If voltage is not found inspect the ORANGE splices circuits LH control assembly and ignition switch If voltage is found test the BROWN ground circuit Verify there is continuity between the circuit and chassis ground If all circuits function remove the speed sensor from the transmission Verify the sensor is not damaged Test the speed sensor using the following tools Hall Sensor Probe PN 2460761 Static Timing Light Tool PN 2871745 Connect the tools together as shown below RED STATIC TIMING LIGHT TOOL 2871745 HALL SENSOR PROBE 2460761 Insert the sensor probe s 3 terminals into the speed sensor as follows WHITE wire into pin C BLACK wire into pin B RED wire into pin Verify a good 9V battery is connected to the timing light tool Pass the blade of a screwdriver back and forth across the sensor tip The timing light tool LED should illuminate each time the blade passes the sensor face 10 If the test fails replace the speed sensor 12 19 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL REAR DIFFERENTIAL SOLENOID X2 If the rear differential fails to switch from operational modes 2 Check the solenoid and relay connectors Look for Operation Overview loose wires or bad connections The differential solenoid is located on the rear gear case Refer Check f
69. teering Relay Motor Head lights 20A Lights Tail lights Brake lights AWD Coil ADC Coil 20A Drive Rear Differential Solenoid X2 RH AWD ADC switch Winch Switch Power 20A Accessory All accessory power point pigtails 20A Flasher TO INT L Models Hazard and Flasher circuits 12 24 FUSE BOX LAYOUT The fuse box is located under the front rack or storage box To gain access remove the front rack or storage box assembly by unlatching the two locking anchors The cover label identifies the location of each relay and fuse BUMPER FAN tH LIGHTS N RELAY RELAY RELAY WIRES LIGHTS DRIVE ACCESSORY CHASSIS 20 20 20A RELAY EFI UNSWITCH EPS R 204 10A 304 t INT L Models SPARE 30A SOLENOID ia WRES gt LIGHTS DRIVE ACCESSORY CHASSIS 20A 20A 20 RELAY EFI UNSWITCH FLASHER 10A 20 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL LIGHTS Headlight Adjustment The headlight beam is adjustable 1 Place the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall 25 ft 7 6 m 2 Place the transmission in neutral and lock the parking brake 3 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height NOTE Rider weight must be included on the seat while perf
70. ttery cable starter motor or starter solenoid see Voltage Drop Tests Faulty key switch or Off Run Switch Faulty transmission switch Faulty Start Diode s Use a digital multi meter to test diode operation Locate the diode s in the main harness under the hi temp conduit and measure between the diode connections Continuity should flow one direction only Faulty starter solenoid or starter motor Engine problem seized or binding can engine be rotated easily Starter Motor Turns Over Slowly Battery discharged Excessive circuit resistance poor connections see Voltage Drop Test Engine problem seized or binding can engine be rotated easily Faulty or worn brushes in starter motor Starter Motor Turns Engine Does Not Rotate Faulty starter drive Faulty starter drive gears or starter motor gear Faulty flywheel gear or loose flywheel Voltage Drop Testing The Voltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection will appear as a high voltage reading Voltage shown on the meter when testing connections should not exceed 0 1 VDC connection or component To perform the test place the meter on DC volts and place the meter leads across the connection to be tested Refer to the chart on 9 35 to perform voltage drop tests on the starter system Voltage should not exceed 0 1
71. ual are obtained with a Fluke 77 Digital Multimeter PV 43568 This meter is acceptable for use when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multimeter reading K ae Starter M etc and the position of the decimal point Motor For resistance readings isolate the component to be Stator tested Disconnect the wiring harness or power supply Power Steering Connector Unit EPS under side panel Component Locations Differential Solenoid attached to rear gearcase LH Control RH Control Instrument Headlight Switch Cluster ADC AWD TURF Mode Rev Switch Override Button Engine Stop Switch Key Switch Diff Solenoid Relay 12 3 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL INSTRUMENT CLUSTER XP EPS MODELS Overview The instrument cluster displays critical vehicle information to the user Reference the following page for display functions and descriptions NOTE Some features are not applicable to all models IMPORTANT The use of a high pressure washer may damage the instrument cluster Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the instrument cluster lens Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens
72. when the RH control switch is in either 4x4 or ADC 4x4 position 14 TURF Indicator Illuminated when the RH control switch is in the TURF position X2 Models Only 15 Neutral Gear Indicator LED illuminated when gear selector is in the neutral N position 16 Gear Position Indicator Displays gear selector position H High L Low N Neutral R Reverse P Park Error shifter stuck between gears 17 Power Steering System MIL LED illuminates when a fault has occurred with the power steering system The LED will illuminate when DTC display mode is active 18 Turn Signal Hazard Lamp Indicator International Models Only LED illuminates whenever the LH RH or hazard lamps are activated 12 5 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRICAL Speed Information The top section of the instrument cluster is dedicated to displaying either vehicle speed or engine RPM 1 Select N or P gear position Function will not work through REVERSE OVERRIDE button when reverse gear is selected 2 Press and release the MODE button on the instrument cluster or press and hold the LH control REVERSE OVERRIDE button for more than 1 2 second to toggle between vehicle speed and engine RPM displays NOTE Mode button on instrument cluster is locked out when vehicle speed is above 15 MPH Information Display Area The center of the LCD is the information display ar
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