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Polaris Digital Wrench

1. Isolate Tests What does passing this Pet rim AWD switch and power sources are functioning properly What does failing this test indicate Problem is between this point and the battery Rectifier Test The Vehicle Home Page is a new feature in version 3 and it replaces the Manual Browser and Diagnostic Procedures screens used in previous versions All service documentation diagrams and Guided Diagnostic Procedures are available from this single location uousJM jexibig BUISN iQ uonosee The screen is split into two components A table of contents for the selected vehicle 1s arranged in a tree view on the left side of the screen The right side of the screen is a display area that operates in much the same way as a web browser Main topics are shown as a book icon in the tree view Double Click on a topic or on the and symbols to expand and contract the topic Documents and other information are shown as a page icon Click on the document title to open the information in the display page Vehicle Home Page Content Local vs Web There are two possible sources of the information shown on the Vehicle Home Page When Digital Wrench is first installed the documents displayed are those that are stored on the PC hard disk If the content source is changed to Web on the Configuration screen the information will be loaded from the Digital Wrench Home Page on the Inter
2. papes Dunes iy uoj2es 5 Locate EFI Diagnostic System select it with the mouse and then press the Add Remove button 6 Follow the instructions given in the uninstaller Occasionally problems occur during the uninstall process If there are error messages displayed once the uninstall process is complete make sure all files have been deleted from the EFI Diagnostic System Folder Normally this folder is located in C Program Files EFI Diagnostic System To uninstall Version 1 software versions 1 01 and 1 20 1 Select the MStar button 2 Select Settings and Control Panel 3 Select Add Remove Programs 4 Locate Polaris Diagnostic System 1f removing version 1 20 or MSE Diagnostic System 1f removing version 1 01 select it with the mouse and then press the Add Remove button Occasionally problems occur during the uninstall process If there are error messages displayed once the uninstall process is complete make sure all files have been deleted from the Program Folder 15 Section 4 Getting Started Connecting the Vehicle Interface Cable The Interface Cable must be connected to the proper communications port on the PC as well as the vehicle being tested The cable can be connected and disconnected at any time although it s usually best to leave it connected to the PC at all times see note below Connecting to the PC The PC end of the Interface Cable has a 9 pin D SUB connector on it whi
3. then you can simply select the Click here link at the bottom of the screen to get to the registration Web Site Enter the License ID and other information on the Web Site Once you have been provided a Registration Code enter this code on the Registration Screen and select the Add Button to complete the process Write down your License ID amp Registration Code and keep it in a safe place NOTE The current license agreement allows the software to be registered on a maximum of 3 different PC s within the Same Dealership Trying to register on more than 3 PC s will result in an Invalid License ID error Uninstalling Polaris Digital Wrench Normally there 1s no reason to uninstall the Diagnostic Software When new versions become available they can be installed without having to uninstall the previous version In rare cases where the system has become corrupted it may be necessary to remove the software and then reinstall Follow the instructions according to the version of software you are removing To uninstall Version 2 03 to 2 08 software 1 Select the Astar button 2 Select Settings and Control Panel 3 Select Add Remove Programs 4 If you have more than one serial number installed you may see entries called EFI Diagnostic System Option Pack For each of these entries click the Add Remove button and follow the instructions If you do not see any such entries proceed to step 5
4. for each item The following control buttons are also available on the grid itself What this button does The Green Check button indicates that the data item is currently enabled and the data values will be updated Clicking on the green check button will disable updates of the particular data value and will increase the update rate of the other items on the grid If you are only watching a few of the data items turning the other ones off will make the remaining items update considerably faster The Red X button indicates that the data item is currently disabled and the data values will not be updated Clicking on the red X button will re enable updates of the particular data value a a large meter of the selected data item single chart of the selected data item 37 youelM jexibig BUISN 6 uonosee Section 5 Using Digital Wrench Data Grid Configuration One of the data items on the Display Grid is always highlighted with a yellow bar This is the Currently Selected item The Yellow Highlight can be moved by either clicking on another data item with the Mouse or using the up down arrow keys on the keyboard The buttons along the right side of the data grid provide control over the position of data items and allow individual items to be added or removed from the grid Different Data Grid configurations can also be saved and restored using the Save amp Load Buttons Refer to the Help System for a
5. a screen of the Guided Diagnostics Screens Displays a picture related to the Instructions or Measurement being performed Displays a Wiring Diagram related to the specific circuit being tested Backs up in the procedure to the previous step Note that the previous step may not be the previous screen Often the Backup Button will move back several screens Exit the Diagnostic Procedures Section 5 Using Digital Wrench Guided Diagnostics Screen types There are several different types of screens used in the Guided Diagnostic Procedures Instruction Screens are used to give you a Instruction Screen message or to instruct you to perform some operation Measurement screens lead you through a Measurement Screen multimeter measurement and provide a list of possible measurement results to select from Onesion Seren Question Screens ask you a question and provide a list of possible answers to select from Data Screens retrieve Data Items from the Data Screen Engine Controller and make decisions based on the value of that data Trouble Code screen Trouble Code Screens retrieve Trouble Codes from the Engine Controller for evaluation Conclusiom Sereen This screen displays the final diagnosis of the problem 52 Instruction Screen Instruction Done Continue e Instruction Screens will look similar to the example above They will give you some piece of information instruct you to do something or just ser
6. and the Ignition On before you can proceed from this screen If there are communication problems the Continue Button will be disabled and you won t be able to move on to the next step e There are some situations where a Data Screen will automatically continue when a specific condition 1s met such as the Engine 1s started Most of the time however the Continue Button should be pressed to proceed Dateien The Data Item Area will display the value of a particular Sensor or other Data Item Instruction Continue Button The Instruction Area will contain any instructions or actions to be performed while on this step Once all the actions have been performed select the Continue Button to proceed to the next step The Continue Button is used to proceed to the next step When the button 1s pressed the current value of the Data Item Area will be stored and used in any decisions Trouble Code Screen Trouble Code e The Trouble Codes Screen requests Trouble Code Information from the Engine Controller and makes decisions based on what Trouble Codes are set The screen may or may not be visible e The Interface Cable must be connected and the Ignition On before you can proceed from this screen If there are communications problems the Continue Button will be disabled and you won t be able to move on to the next step yYoudlM jexiBig BUISN 26 uonoee e An invisible Trouble Code Screen will only take a sho
7. bring up the Trouble Code Information Screen The Trouble Code Information Screen contains more specific information about the particular fault code along with possible causes There may also be a Wiring Diagram Button j present on this screen If this button is enabled i e not grayed out then there is a wiring diagram available The Guided Diagnostics Button will be enabled when additional Guided Diagnostics Procedures are available for this Trouble Code Selecting the button will begin the diagnostic procedure Refer to the Guided Diagnostics Section in this manual or the Software Help System for more information on Guided Diagnostics Clearing Trouble Codes 36 The Clear Trouble Codes Button on the Trouble Codes Screen can be used to erase any Historic Trouble Codes from the Engine Controller Memory Only those trouble codes which are marked as Historic will be erased Current trouble codes cannot be erased from the controllers memory until the cause of the trouble code has been repaired POLARIS A af Sync Counter i Acceleration Enrichment The Data Display Grid Screen shows various sensor values as well as the critical operating parameters of the engine control system The display 1s arranged in a grid format where all the information can be seen at one time The grid shows the data item name current value as well as the units of measure 1 e volts degrees etc
8. more detailed description of how to modify the Data Grid Configuration What this button does 38 The Up Button moves the Selected Data Item highlighted in yellow towards the top of the list The Down Button moves the Selected Data Item highlighted in yellow towards the bottom of the list The Add Button opens up a menu of additional data items that are available to be added to the Data Item Grid display Ifthe display is already full 14 items one item must be removed before adding a different one The Remove Button removes the currently selected data item from the display The remaining items will expand to fill the space The Save Button opens a menu where the current list of displayed items can be saved The Load Button displays the list of saved Data Grid Display configurations Select one of the saved configurations from the list to restore the Data Grid layout to the way it was when the configuration was saved Data Controls The Data Recording Controls are located on the bottom of many of the data display screens These controls can be used to capture important events in the engine controller data and review back through the information to see the data over a specific period of time The following buttons and controls can be used to start and stop recording as well as review the recorded information What This Button Does The Mark Button can be used to mark a certain point in the recorded data
9. move through and view the recorded data What This Button Does The Slider Bar shows the position of the currently displayed data relative to the time when the first data was recorded The Slider Bar will move to the right as more data 1s recorded and will stop moving when the Stop button has been pressed Once the Stop Button has been pressed the Slider Bar can be used to move around within the recorded data Simply click on the Slider Bar and while holding the mouse button down move to the left to view older data and to the right to view newer data items a The Previous Data Item Button is located on the far Left of Section 5 Using Digital Wrench the Record Control Once the Stop Button has been pressed this button can be used to move to the previous data item step by step each time the button is pressed The Next Data Item Button is located on the far Right of the Record Control Once the Stop Button has been pressed this button can be used to move to the next data item step by step each time the button is pressed The Trigger Point Marker will be shown on the Record Control when either the Mark Button has been pressed or an Automatic Trigger has occurred This marker shows the point in time when the Mark Button was pressed or when the Automatic Trigger happened 40 and Meters _ 0 i i m e 138 137 138 138 140 141 142 143 144 145 148 Time Seconds The Data Chart Screen displays a single data item in a cha
10. the Getting Started Prompt On or Off Help Controls weather the Vehicle Home Page content is loaded Content from the PC hard disk Local or from the internet Web instead 48 Vehicle Home Page Wrench POLARIS 2 4 Sportsman 500 Carb SANJ Diagnose amp Repair 2 6 Drive EH AWD SYSTEM J System Overview 49 Illustrate Block Diagram Isolate Tests 49 Electrical Control 49 Illustrate Block Diagrams L Mechanical Control 3 49 Illustrate Visual Inspection 3 49 Isolate Test 4 Chassis EHAN Electrical Isolate Tests Hub Coil Resistance Test Test Name Hub Coil Resistance Test Check resistance of hub coil Resistance should be between X Ohms and Y Oluns to pass Otherwise Test Procedure fail What does passing this test hu Hub coil circuit is complete What does failing this test indicate Hub coil has opens or shorts 4 4 DC CDI IGNITION SYSTEM J DC CDI Ignition 49 Illustrate Block Diagrams Voltage at Hub Coil Test Tesi Name Voltage at Hub Coil Test Disconnect speedometer connector at front panel and check for battery voltage at hub coil connection See photo Voltage should be near battery voltage to pass Otherwise fail Isolate Tests Test Procedure 40 Power Distribution Module Sp amp d System Overview 4 Mustrate Block Diagram
11. where a significant event occurred such as a misfire or other fault When this button is pressed the Trigger Point Marker will be displayed on the Record Control to show the point in time when the button was pressed Once the Mark Button has been pressed data will continue to be recorded for a short time and will then stop to allow the recorded event to be reviewed This button will only be enabled when data is being recorded Once it has been pressed it cannot be pressed again until the Go Button has been selected to restart the recording process The Go Button can be used to restart the display and recording of data after the Stop Button has been pressed When the Go Button is selected all previously recorded data is erased and the recording process begins again This button will only be enabled when the display of live data has been stopped by selecting the Stop Button or shortly after a Trigger Point has occurred The Stop Button can be used to stop the display of live data and allow the recorded information to be reviewed using the Record Control This button will only be enabled after the Mark Button has been pressed 39 youelM jexibig BUISN 26 uonosee The Record Slider Control The Record Control can be used to move through recorded data once the Stop Button has been pressed The numbers at the bottom of the Slider show the time in seconds since recording started There are several ways to
12. you through the installation of Polaris Digital Wrench 3 0 694 It is recommended that you clase all other applications before starting Setup This will make it possible to update relevant system Files without having bo reboot your computer Click Next ka continue Cancel Setup is now ready to begin Click Next to continue papies bupj329 iy uoj2es Section 4 Getting Started 10 This screen displays the Software License Agreement After reading and agreeing to its terms Click I accept and then Next t Polaris Digital Wrench 3 0 B94 Setup a license Agreement linia ror Please review Ehe license terms before installing Polaris Digital Digital Wrench Wrench 3 0 B94 Press Page Down to see the rest of Ehe agreement PLEASE READ THIS LICENSE AGREEMENT CAREFULLY BEFORE YOU INSTALL THIS SOFTWARE BY CONTINUING THE INSTALLATION YOU CUSTOMER ACCEPT THIS AGREEMENT IF YOU DO NOT ACCEPT THIS AGREEMENT PROMPTLY RETORN THE CD ROM TO YOUR DISTRIBUTOR OR ROBERT BOSCH CORPORATION OR ERASE ALL DOWNLOADED FILES FROM YOUR SYSTEM 1 DFFTRTTTORS IF you accept Ehe terms of the agreement select the First option below You must accept the agreement to install Polaris Digital Wrench 3 0 B94 Click Next bo continue OI do not accept the terms in the License Agreement 6 Now it s time to choose the folder on your PC in which Polaris Digital Wrench will be installed In most cases the default
13. Customer Vehicle g Vehicle Home Page Delete 11122006165521 Martha Crosscountry 2007 Ranger Ranger 700 XP EFI hai Vado Sthacticn Delete 01262006235052 Tohn Q Sledrider 2007 Snow 600 700 CFI IQ RMK SB Dragon aw Customer Information R Product Utilities Digital Wrench Help Exit First lt Prev Next gt Last gt Version 3 0 B94 e Vehicles may also be selected by opening existing cases Cases are stored anytime vehicle and customer information is entered and are kept on the hard disk 3l Yous jexibig BUISN iQ uonoee Customer Information Screen Quick Start Digital Wrench ASK Form Venicle Home Page solve Explair pair Te el Vehicle Selection Customer Information k d Customer Information Name John Q Sledrider 4 amp Product Utilities CES Rp Arctic Circle E Digital Wrench Help City Realycold State Prov MN Zip Post Code 59999 E mail Address oofestBsubzeronetnet Phone o Fax fp lt Prev Next gt Version 3 0 B94 Section 5 Using Digital Wrench e The Customer Information Screen is used to enter general information about the vehicle owner The information 1s used on the ASK form and is stored in the Case File on the hard disk e Entering customer and vehicle information is not required for the system to operate properly but adding the information will make printed reports more useful e Toenter inform
14. ER TO INSTALL FUTURE PROGRAM UPDATES papies Dunes iy uoj2es Section 4 Getting Started Installing Polaris Digital Wrench The process of installing Polaris Digital Wrench may be slightly different depending on the operating system version installed on your PC The following steps will take you through the normal installation procedure If message boxes appear that are not described in this section look in the section entitled Possible Messages and Errors to get a full description of each message or error IMPORTANT While installing you may be asked if you want to remove older versions of Digital Wrench Software Normally removing an older version is the best thing to do but there may be circumstances where it is needed for other product lines When in doubt don t remove the older version Windows NT 2000 XP You must be logged in as an Administrator or have Administrator Rights to install Digital Wrench Software Attempting to install the software without Administrator Rights will most likely result in errors when trying to run the program starting the Install Process 1 Insert the Polaris Digital Wrench CD into the CD ROM drive of your PC In most cases the setup program will run automatically Once the CD has been inserted wait a few seconds for it to spin up and start the setup program 2 If the setup program does not start then push the lista Button and select Run In the window that comes up type D Setu
15. I ais 53 Nea ar ne o ESC TE oops ode i i a a IERI IE oM UU eee 54 OUSSUOH Cir Aaaa ia aso Ed bus Go iM NM i a a Ma EU MCHU 55 Data SCT CSU pee centenis emet tup i OD o IM a a S 56 Trouble ude e E 1 r 57 anis IS TO SC EC ul a E o 58 die 0103 Las na e ia L a rr ee eee ee ene r 59 ber GB UE UE iii ii ii iii i i i see i i i 60 In CNB a o M i EPs 60 Internet Explorer and Acrobat Reader Install Problems e 60 Diagnostic System Install Problems 4e enne tania t oe eua eon bata asis ias aHa 60 Lope aO se oi oe totu RR HIdeIERRDATURDAIQIESEISMENNEE EVE MESUKHINENS 61 Comimstatus No Cable or POWGE ceret ep picetitetr teo eesin eee E CER Eta UH 61 Commstatus Always Initializing Communications 62 Communications often lost and Re initializing eeeeeeeeeeeeeeeeee 62 ulai is TP aa e thin ERI REC PPLH REEL PPR 63 No Comm Ports Available on this Computer cccccccccccccccceceeeeeceeeeeeeeeeeeeeeeeeeees 63 The Selected Serial Port x is already 1n USC reni n nna 64 bystem C OBDIP urdtioH By AUG ass ss i o a bp a nih 64 This manual has been written to help you understand the all the functions and capabilities of Polaris Digital Wrench in order to gain the maximum benefit from the product The manual 1s divided into 5 parts Introduction The Introduction provides an overview of the functions of Digital Wrench and its uses Special S
16. PU 47471 omartLink Module 01 10005 PU 47468 Vehicle Interface Harness CAN Based Systems 01 10004 PU 47469 SmartLink Serial Cable 01 10006 PUATATO SmartLink Connections Connect the Vehicle Interface Cable to the 15 pin connector on one end of the SmartLink Module and the serial cable to the other end Make sure the screws at each end are tight to prevent damage to the connectors Refer to the diagram on the following page Connect the SmartLink Serial Cable to the same serial port used by other diagnostic cables and connect the vehicle interface cable to the vehicle diagnostic connector Care and Maintenance of the SmartLink Module Unlike previous interface cables the SmartLink Module contains a microprocessor memory amp other sensitive electronic components e DO NOT under any circumstances open the module Static electric discharges will permanently destroy the device e Do not allow the SmartLink Module to become wet or operate it in a wet environment e Always keep both the Vehicle Interface and Serial Cable screws tight to prevent damage to the connectors e Do not attempt to lengthen the Interface Cable between the SmartLink and the Vehicle or communication errors will result 18 Connect to Digital Wrench PC B Serial Interface Cable to PC PU 47470 DSA PN 01 0006 9 Pin Connector for Connection to the Digital Wrench PC e x LLL Status LED Blinks continuously if a problem
17. Polaris Digital Wrench POLARIS mum Quick Start vehicie Home Page Quick Start Selection Pn Vehicle Selection k d Customer Information s R Product Utilities Digital Wrench Help rx 98 Start a New ASSERT Case Load Current Last ASSERT Case Version 3 0 2007 Sportsman 800 EFI Deluxe Status Installation Guide amp User Manual System Version 3 MAN gt POLARIS 73 The Way Out Tg PELARI m iF 4 4 Diagnostic gt T Systems k d e E t es Table of Contents PONG DAVES WV UATE AN TM 1 EEE CGI L ats i ia a a i load i ss a o a sa i e i a a i 3 PC Minimum I CAM ide ILS essiri ii Nei a i a 4 special O CL Miorma ii iii i i 5 Bere Using Digital TEC EE e aenerequcenceteeease ease MU 5 Gem suo Considero co cerssesarveeseeaeresencinwewniptieaieumaeeean 3 Safety Considerations for the Vehicle Interface Cable 6 CUN ey UE los essere pasti A y O IM a MISES 7 VT eese sioe peste puero ii a DM Rte AUR dm i 7 Installing Polaris Digital URGED i iais a o p 8 Stalino The Install PTO SScosncssase pne meum ET UDIN MINE 8 Possible Messdees and OG Assisi EE 12 Pe T8 SONATE aese EE R 13 Entering The Software Serial Number eesssseeeeeeerrenr 13 Reer trins he OT MB ri iii poti E r ii 14 Uninstalling Polaris Digital VW 06th a sisikijonisiinisonisinsas i niinsisoiaiiss 15 Connecting the Vehicle Interf
18. SmartLink Module Software and the device must be reprogrammed or repaired Configuration and Utilities Information on the current SmartLink Module software as well as access to the reprogramming utility are located on the Digital Wrench Configuration Screen Select the SmartLink Configuration button on the bottom of the Configuration Screen to access these functions Only reprogram the module if the LED 1s flashing or when new SmartLink software is released If after successfully reprogramming the SmartLink Module the LED continues to blink rapidly or stays on continuously the module is damaged and must be replaced Difficulty reprogramming the SmartLink may also be caused by serial port communications problems Refer to the Digital Wrench Support Website for details on solving SmartLink problems SmartLink Auto update 20 When a new Digital Wrench version is installed there is often a new version of SmartLink software that goes with it When the new Digital Wrench version detects an older version of SmartLink software a SmartLink out of date message will be displayed and the SmartLink update screen will automatically load and update the module This process will also happen if Digital Wrench detects that the SmartLink module is not programmed correctly Digital Wrench Status Messages When Using the SmartLink Module the following additional status messages may be displayed in the Digital Wrench Status Display Messa
19. ace T ab oe visemes ras 16 Connecting to the OR r 16 Serial Port Adapters USB Serial amp Others seeeeee 16 Serial Port Problems with low power Laptop Computers eeeeeees 17 Conme eino TY CIC ia saaa E een aed a decease 17 Using the SmartLink Interface MOdUIB ee erat bi is iii 18 TC OS eo settee nesses i ed otha muss o a i a cannes 18 S Mar Lim 6 COMM OMS ae no a i a a i a i a 18 Care and Maintenance of the SmartLink Module eeeeeeeeeuuuusee 18 SIS LAC Nd IS aaa o i i fea M M USC secon a i N 20 Connon and EUH S ossibus i i a i i a NU oreo 20 Bi ai Wrench Status INS SAE CS menesdnssveputus epe ie en reis E 21 S EAS LD ene eae a ai i a r a a a i eee a a a 21 Vemo Dinal Vy ront T o ii i i i i ae DEDRKIER RAMIS 22 THE AMD O M ia r T P Communications Stat s Display iei esese sii tbi rire ges daba sued odd avis a bc ES Etc UM pa i sia 23 Ims pun pees pa FEE EM MUR EPi UNI EOnEd dE 24 Using the Keyboard to Run the PEOBDPOHT oc ccecesonicszsacewentasserincrevesecrensaneiedd PA Main Control Panel Keyboard Functions seen 25 Trouble Code Screen Keyboard Functions esses 25 Data Grid Screen Keyboard Functions iecit ie qo ert RE 26 Large Meter Screen Keyboard Functions seen 26 Data Chart Screen Keyboard Funct
20. afety Information The Special Safety Information section covers important 1ssues regarding operator safety while using Digital Wrench as well as instructions to prevent damage to the equipment Getting Started The Getting Started Section discusses installing and connecting Digital Wrench Using Digital Wrench The Using Digital Wrench Section covers all the functions of the system in detail Troubleshooting The Troubleshooting Section provides answers to common problems that can occur while using Digital Wrench This manual covers most of Digital Wrench functions as of the date the software was released For more detailed information or assistance on specific vehicle tests and functions always check the Program Help Click This Button on the Main Screen to open the Help System JEnUCW SI 3noqwv L WOLVES jenueW Siu 3noqy Uogas Polaris Digital Wrench has been designed as a workshop service and information tool for diagnosis and testing of Engine Control Systems and related components There is a large amount of information available from this system including e Diagnostic Trouble Codes e Component specific Wiring Diagrams e Engine Sensor Data e Fuel Injection System Control Parameters e Engine Controller Identification Information e Special Tests and Calibration Procedures e Service Manual and other Documents This software version provides testing capabilities on all Fuel Inje
21. another vehicle damaged The Engine Controller has been Check the Engine Controller power damaged or 1s not receiving circuits Verify operation of the power system with another Engine Controller The Interface Cable has been Replace the Interface Cable damaged Communications often lost and Re initializing There are many situations that can cause communications with the Engine Controller to stop and have to be and re initialized As with other problems it is often useful to verify operation of the system on another vehicle to determine 1f the cause 1s the vehicle being tested or Digital Wrench itself Other programs running in the PC Make sure all other applications are slowing the computer too have been shut down before much or using too much memory running Digital Wrench Check all the wires and terminals Damaged terminals or wires in between the Engine Controller and the Vehicle Diagnostic connector PC Communications Port to make or Interface Cable sure there are no loose or damaged connections The PC does not meet the Make sure the PC meets the minimum requirements for Digital minimum requirements Wrench 62 General Program Problems General Program Problems are those which prevent Digital Wrench from operating properly or operating at all Most problems that affect the operation of Digital Wrench are caused within the PC being used or Operating System configuration problems Many tim
22. ation simply select the box next to the Customer Name Address Etc and enter the required information 27 Trouble Codes Blink Description Status Code Barometric Pressure Sensor Signal High Current TPS Circuit Voltage Low Current f Loss of Synchronization Historic 9 The Trouble Codes Screen provides information on all diagnostic trouble codes stored in the Engine Control Module Each row in the list contains several pieces of information on the particular trouble code e The following Trouble Code numbers may be shown on the Trouble Codes Screen e The type of Trouble Code numbers shown will be different depending on the vehicle engine being tested Code Description Number Blink Code Not Always Displayed The Blink Code column shows the Trouble Code Number that would be blinked out on the Malfunction Indicator Lamp for this trouble code If there 1s no number shown then the particular code does not have a Blink Code Number The Code column indicates the trouble code number associated with a particular fault This 1s usually a two digit number A P Code Number based on SAE standards may also be shown The P indicates that the trouble code 1s related to a Powertrain component P Code numbers used here are similar to the OBD II diagnostic standards used in the automotive industry 33 uyousJM jexiBig BUISN iQ uonosee Section 5 Using Digital Wrench The following additional ite
23. buttons with the mouse or pressing one of the Function keys on the keyboard For example to view the Trouble Codes Screen either select the Trouble Codes Button the button on the far left side or press the F1 key on the computer keyboard A list of all the buttons their corresponding Function Keys and a description of what each button does 1s found in the chart in the Main Control Panel Buttons Section later in this chapter The Communications Status window is also always visible in the lower left corner of the Main Control Panel Communications Status Display The Communications Status Display is located in the bottom left portion of the Main Control Panel All messages regarding communications to the Vehicle Engine Control Module will be displayed here The following messages may be shown Note Refer to the Troubleshooting Sections in this manual and the Help System Help Button for more information on Solving Communications Problems Status Display starting Up Initializing Communications Not Connected No Cable or Power Connected Wrong Vehicle Selected No Response From ECU Meaning This message is briefly shown when the system 1s first started and indicates that the software is setting up the communications interface cable This message will be shown any time communications to the ECU 1s being initiated This will happen when the cable is first connected or whenever communication
24. ch must be connected to a serial communications port on the back of the PC If there is more than one serial port available the cable must be connected to the same serial port as the one selected in the System Configuration Screen The Serial Port Connector on the back of the PC should look very similar to the picture below Most serial ports have a 9 pin connector although some use a 25 pin type If the serial connector on the PC has 25 pins then an adapter must be used to convert the 25 pin connector to a 9 pin type before the cable can be connected 25 to 9 pin serial adapters are available at nearly all computer stores Important It is very rare to find 25 pin serial connectors on modern PC s Do not mistake the 25 pin Parallel Printer Port also called LPT for a serial port Connecting to the Parallel Printer Port will not work The first time Digital Wrench is run the communications port used to communicate with the ECU through the Interface Cable will not have been selected yet Note Direct Injection Watercraft and 1999 2000 Victory Motorcycles utilize completely different Interface Cables than the one normally used with Digital Wrench Refer to the Help System Setup and Configuration section for detailed information on connecting to these vehicles serial Port Adapters USB Serial amp Others 16 For PC s and Laptops that do not have a built in serial port you will need to use a serial port adapter in orde
25. close Digital Wrench and shut down communications to the Vehicle 50 Guided Diagnostics Introduction Guided Diagnostics provide step by step procedures for diagnosing faults in the EFI or other systems The Guided Diagnostic Procedures take information normally provided in a Flowchart or Trouble Tree format and presents each step of the process as a single screen of information Done Continue Each step of a diagnostic procedure provides Instructions on actions to take Measurements to be made Questions to be answered or will display Diagnostic Conclusions Important Considerations e Always read all instructions presented carefully and completely Failing to perform the instructions exactly as written is guaranteed to produce incorrect diagnostic results e Don t skip steps unless you are absolutely sure that it won t affect the outcome of the test e If you are going to go back through a procedure and restart testing from an earlier point always undo any instructions given when you originally went through the steps For example 1f you are backing up through a step that instructs you to disconnect a connector reconnect it before backing up further If you are unsure about a diagnostic conclusion it s usually best to reconnect everything and restart the procedure from the beginning 51 Youd jexibig BUISN iQ uonoee Common Buttons The following buttons are located along the bottom right of
26. cted Polaris Vehicles from model year 1999 to the present Version 3 0 also provides access to documentation and test procedures for carbureted vehicles through the Vehicle Home Page and ASSERT functions Additional vehicles and functions will be added to future versions of the software Always refer to the Help System for the latest software function descriptions and vehicle coverage Uononpomuj 7 WOES Section 2 Introduction PC Minimum Requirements Before installing Polaris Digital Wrench please ensure that the PC meets the following minimum requirements General Requirements Windows 2000 XP Vista Windows 7 operating systems Minimum Pentium 233 MHz or equivalent Processor Standard Serial Port RS 232 CD ROM Drive SVGA Monitor and Video Card capable of 800 x 600 pixel resolution e Polaris Digital Wrench requires 200 Megabytes of Hard Disk Space If Internet Explorer must be installed an additional of 75 Megabytes is required to complete the install If Adobe Acrobat Reader 1s required an additional 45 Megabytes of needed So in total it is possible that 320 Megabytes of Hard Disk space will be required e Additional Hard Disk space will be needed to install Information System Documentation and Service Manuals The minimum amount of space 1s dependent on the particular service manual installed Windows 95 98 Windows ME Windows NT e Windows 95 98 Windows ME and Windows NT are no longer sup
27. e Engine Controller this screen will appear uouosJM jexibig BUISN 26 uonosoee e To fix this problem make sure the software is communicating with the Engine Controller Most often the problem 1s that the Ignition is OFF or the Interface Cable 1s not connected e Ifthe Waiting for Communications Screen appears while the Engine 1s Running at High Speed greater than 1800 RPM it may be necessary to return to Idle to allow communications to be reestablished e Also in situations where you have used the Backup Button to move back to previous steps in the procedure it 1s very likely that one or more connectors have been disconnected preventing communications with the Controller Whenever using the Backup Button it is important to undo any instructions that were performed as you backup through each of the previous steps e Ifthe software is communicating with the engine controller and the Waiting for Communications Screen still appears try closing the Screen and run the chart again 59 Section 6 Troubleshooting Install Problems Problems with installing the software can be caused by a variety of things and the solutions depend on where the problem occurred e Errors during install are most often caused by a damaged or dirty Install CD Always handle the CD carefully and make sure there are no fingerprints on it e Errors during install can also be caused by problems on the PC Hard Disk If problems with the Hard Disk are su
28. e data item to trigger on from the list 3 Enter the type of comparison Equal to Greater Than or Less than 4 Enter the Value to Compare to in the Value Box using the keyboard 5 Finally select the Arm Trigger Button xs to set up the trigger and proceed to the Data Display Screen Section 5 Using Digital Wrench 46 Special Tests Menu Selecting the Special Tests Button on the Main Menu will bring up the Special Tests Menu for the currently selected vehicle The Special Tests Menu displays a list of any special tests or procedures available for the vehicle being tested uouosJM jexibig BUISN 26 uonosoee The number of available tests shown on the menu will be different depending on the Vehicle being tested Refer to the Digital Wrench Help System for more detailed information on Special Tests amp Functions for specific vehicles A test procedure can be selected through a number of methods e Click on the number next to the test you want to run Double click on the text for the test Pressing the number of the test on the keyboard Use the arrow keys on the keyboard to move to the desired test and then press the Enter key Click on the X in the upper right corner or hit the ESC key on the keyboard to close the Special Tests Menu without running any tests Note The Feature Configuration Registration selection shown at the bottom of the Special Tests Menu is used to access the software Regi
29. e itself Don t allow the cable to lie on the floor near or in puddles of water Water can leak into the circuitry through the connector and damage the cable What s Included The Complete Polaris Digital Wrench Kit includes The Vehicle Interface Cable The Vehicle Interface Cable 1s used to connect the computer to the vehicle being tested Additional Diagnostic Adapters Optional Some vehicles require additional adapters to connect the Interface Cable to the Diagnostic Connector Different adapters are included with the software depending on which Diagnostic Kit was ordered The Polaris Digital Wrench CD The Polaris Digital Wrench CD is used to install Digital Wrench onto the computer Always keep this CD ina safe place in case the software needs to be reinstalled or moved to a different computer The User Manual and Install Guide this book Your Polaris Digital Wrench Serial Number s The Polaris Digital Wrench Serial Number is necessary to install and register the software The Vehicle Interface Cable The Vehicle Interface Cable 1s used to connect the computer to the vehicle being tested The Digital Wrench Update Kit includes The Polaris Digital Wrench CD The User Manual and Install Guide this book WARNING Do not lose the Serial Number It is the license number for the software and without it the software cannot be re installed or updated at a later time YOU WILL NEED THE SERIAL NUMB
30. e list Right Arrow Key Move to the previous Data Item in the list Left Arrow Key Move the Second Chart to the next item in Alt and Right the list Arrow Keys together Move the Second Chart to the previous Alt and Left item in the list Arrow Keys together Mark a point on the Data Recorder press the Mark Button Stop Data Recording press the Stop lt Button Start Data Recording press the Go Button Close the Screen YoUudlM jexibig BUISN 6 uonosee Sensor Data Screen Keyboard Functions To perform this function Press this Key Mark a point on the Data Recorder press the Mark Button Stop Data Recording press the Stop Button X Start Data Recording press the Go gt Button Close the Screen 2 Section 5 Using Digital Wrench Introduction to ASSERT and Satisfy Digital Wrench 3 0 was specifically designed to help technicians fix it fast and right the first time It uses the ASSERT and Satisfy troubleshooting methodology to help diagnose both EFI and non EFI systems This powerful new version not only aids diagnosis but also provides a step by step process you can follow to ensure total customer satisfaction It does this by creating a unique work order for each customer case that stores information about the customer complaint cause and correction So what is ASSERT and Satisfy Simply stated it 1s a 7 step disciplined approach to problem solv
31. e these functions 44 The Trigger Setup Screen allows the software to be set up to capture certain events based on specific trigger criteria Triggers can either be the point where a Trouble Code 1s set or where a specific data value is greater than less than or equal to a particular value The Clear Trigger Button can be used to clear out any previously set up trigger points Select the Exit Button to close the Trigger Setup Screen without setting a trigger Once a Trigger has been set up you will be returned to the Data Display Grid Screen Now that a trigger has been set there will be an additional item on the screen in the lower left corner This Check Box tells you that triggering is ON and as soon as the trigger conditions have been met the data will be captured If you want to disable the triggering simply click on the checked box with the mouse to turn triggering OFF 45 uousJM jexiBig BUISN iQ uonosee Trouble Code Triggering 1 Triggering on Trouble Codes is done by first selecting the Button 2 Next select the trouble code you want to use as a Trigger or select Any Trouble Code to trigger when any trouble code sets 3 Finally select the Arm Trigger Button S to set up the trigger and proceed to the Data Display Screen Data Item Triggering 1 Triggering on a data item is done by first selecting the Button 2 Next Select th
32. e will cause communication problems as well as produce invalid test results General Safetv Considerations uopeuuoju K3ejee jeroede uonoee Note the following safety items related to motor vehicles and internal combustion engines Always make sure an approved exhaust ventilation system is being used and the work area is well ventilated whenever working with a running engine Carbon monoxide is an odorless colorless gas that is extremely poisonous that can lead to serious injury or death Always stay clear of moving parts on a running engine and remove all loose clothing that can be caught in rotating parts Always wear approved safety glasses Exercise extreme caution when working around acid filled wet cell batteries These types of batteries produce a highly explosive hydrogen gas that can cause the battery to explode without warning Section 3 Special Safety Information safety Considerations for the Vehicle Interface Cable 0 or other moving parts of the vehicle being tested Don t allow the cable to come near to or in contact with 5 hot engine components such as the exhaust manifold or engine block Never allow the cable to lie near or on any ignition system components such as Ignition Coils or Spark Plug wires The Interface Cable is shielded from most types of electrical interference however damage to the cable and or the PC will result if ignition voltages are discharged into the cabl
33. een and under the Quick Start Menu ASSERT Cases may also be printed out by selecting the print button while one of the ASK form pages is displayed A blank form can be printed if desired by selecting a new vehicle and then selecting the print button Filling in the ASK form pages and following the ASSERT process can greatly increase both the speed and accuracy of diagnostics as well as provide a record of the process to the customer Program Functions Vehicle Selection Screen Quick Start Digital Wrench ASK Form G Vehicle Home Page xplai Repa P Vehicle Selection Vehicle Information k d Customer Information Product Line Description A Select Product Select Description GR Product Utilities ATV 600 700 CFIIG RMK SB Dragon Y Digital Wrench Help H Exit Model VIN Miles Hours Would you like help with connecting to this vehicle 3 Would you like help with using Digital Wrench Prev Next gt Version 3 0 B94 e The Vehicle Selection Screen is used to select the vehicle being tested e Select the Model Year Product Line and Description by clicking on the lists shown on the screen e Ifthe system 1s configured with Start up Help enabled additional icons will appear at the bottom of the screen where you can get help on connecting to the selected Vehicle zi Quick Start Digital Wrench ASSERT Cases Current Work Order New Work Order Case
34. eiving power connector terminals are not damaged Try from the vehicle Digital Wrench on another vehicle to verify its operation The PC Communications port Verify the proper operation of the has been damaged or the communications port using a PC Operating System diagnostic application configuration 1s not correct The interface cable has been Replace the Interface Cable damaged Note If there is an Icon like M6 on the screen near the system clock then the Palm Pilot HotSync Manager is running and may be using the same port as the Diagnostic Software Close the Palm Pilot software and try again 61 Section 6 Troubleshooting Commstatus Always Initializing Communications This message 1s generated when Digital Wrench has detected a powered Interface Cable and 1s attempting to initialize communications with the Engine Controller The Engine RPM is too high Communications cannot be initialized if the engine 1s running at high speed Bring the engine back to idle until communications status is again Connected Turn the ignition key on and make The Vehicle Ignition Key is off or sure any special procedures or a diagnostic jumper has not been jumpers necessary to test the properly installed particular vehicle have been properly installed The communications circuit Check the wiring and connections between the Diagnostic Connector Verify operation of the system on and the Engine Controller 1s
35. endly and applicable to more models 29 Section 5 Using Digital Wrench The ASSERT Process and ASK Form 30 Quick Start e Vehicle Home Page i i gt Vehicle Selection PR od L k d Customer Information R Product Utilities H Digital Wrench Help System Help Digital Wrench Home Page Digital Wrench Knowledge Base B Exit POLARIS Description of complaint Vehicle use C Recreation C Agriculture C Commercial C Racing C Miltary Does Check Engine Light come on C Yes C No Condition 1s C Continuous C Intermittent C Within 3 days C Within 2 weeks C Within 1 month E T anans When did problem first occur Prev Next gt Version 3 0 B94 The ASSERT Process and ASK form have been integrated into Digital Wrench as part of the main screen shown when the software is started Once a vehicle has been selected the ASK form is available by selecting one of the buttons shown along the top of the screen Each of the ASSERT Steps 1s represented by a button Ask See solve Explain Repair amp Test where the information relevant to that portion of the process can be entered As the information 1s entered into the ASSERT pages it 1s added to the currently active Case File and stored on the vehicle hard disk These cases can be retrieved later by selecting the case file from the Select Existing Case function shown on the start up scr
36. es if Digital Wrench will not run properly rebooting the PC may resolve the problem In extreme cases it may be necessary to completely re install the PC operating system and or service packs as well as Digital Wrench itself to restore any damaged or missing system files No Comm Ports Available on this Computer If the following messages appears when the program is run for the first time Shut down other applications or unplug some other device Then restart the Diagnostic System HuljoouSss GNnolL 9 uonoee OK This means that there are no available communications ports available on the PC and the system will not be able to communicate to the Interface Cable This situation can occur when other applications that use serial communications ports are running and have taken all the available ports on the PC Make sure there 1s at least one free port that no other applications are using and that the Interface Cable 1s connected to this port Note If there is an Icon like M6 on the screen near the system clock then the Palm Pilot HotSync Manager is running and may be using the same port as the Diagnostic Software Close the Palm Pilot software and try again 63 Section 6 Troubleshooting The Selected Serial Port x is already in use Sciial Poll Pioblem When the following messages appears when the program is run sP Unplug the conflicting device or select a different port from the System Config
37. folder is adequate If you want to change this location click Browse If the Diagnostic Software is already installed on your PC this window will not appear k Polaris Digital Wrench 3 0 B94 Setup POLARS Choose Install Location Digital Wrench S ij the Folder in which to install Polaris Digital Wrench 3 0 Setup will install Polaris Digital Wrench 3 0 B94 in the Following Folder To install in a different Folder click Browse and select another Folder Click Install to start the installation Destination Folder C Program Files 05 4 Polaris Digital Wrench Space required 131 6MB Space available 1 006 Click Install to continue 7 The File Copy portion of the install has begun This process may take a few minutes There 1s nothing you need to do during this step Polaris Digital Wrench 3 0 B94 Setup uM Installing inital Wrench Please wait while Polaris Digital Wrench 3 0 B94 is being installed papes Dues iy uoj2es 8 After a short time the Installer will complete and this screen will appear Ifthis screen asks you to restart your computer make sure you restart your computer before using Polaris Digital Wrench b Polaris Digital Wrench 3 0 B94 Setup Sam ASS Completing the Polaris Digital Wrench 3 0 B94 Setup Wizard Polaris Digital Wrench 3 0 694 has been installed on your computer f Click Finish Ea close this wizard IUTE Wrench Polaris Digital Wrench Website Cance
38. ge No Connection To SmartLink No Power to SmartLink Wrong Diagnostic Cable Status LED Meaning The SmartLink Cable 1s not connected to the Serial Port selected on the Digital Wrench Configuration Screen Or one of the older diagnostic cables DI Watercraft Victory etc 1s connected The SmartLink Module is Connected to the Serial Port but it is not powered up On some vehicles the 1gnition key and run stop switches must be on before power is available at the diagnostic connector The SmartLink Module is connected to the Serial Port but the selected vehicle requires one of the earlier diagnostic cables LED State One Flash at Power up and then off Flashing Rapidly Always off Always on Normal Operation The Module is unprogrammed or the software is damaged Reprogram the device No power to the Module check the vehicle interface cable and vehicle harness Or a hardware failure has occurred in the module The module failed to reprogram correctly or a hardware failure has occurred Cycle power to the SmartLink disconnect from the vehicle and reconnect If the LED is still always on then there is a fault in the device 21 papies Dunes iy uoj2es Section 4 Getting Started The Main Control Panel 22 2006 Sportsman B00 EFI Status The heart of the software 1s the Main Control Panel Nearly all functions of the program can be accessed by selecting one of the
39. generated when Digital Wrench cannot detect the presence of an Interface Cable at the communications port selected on the Configuration Screen Some other software is using If you are sure you are connected to a the Comm Port causing the particular Comm Port but you cannot Diagnostic Software to default select this port on the Configuration a different port than where the Screen then the most likely cause 1s some cable 1s connected other software using that port This other software must be shut down before running the Diagnostic Software The Interface Cable 1s not Check the cable connection to the PC and connected to the PC or to a make sure Digital Wrench is configured to different communications port the same communications port than the one selected on the Configuration Screen The Vehicle Ignition Key or Make sure the Ignition Key and or Run Kill Switch is off Run Kill Switch is on A Diagnostic Jumper or fuse Make sure any special procedures or has not been properly installed jumpers necessary to test the particular Frontier ACS Bypass Fuse vehicle have been properly installed bumnoousejqnoJ 9 uomnoee Refer to the Help System for information on these Special Procedures The Power or Ground circuits Verify that the Battery Voltage and in the Vehicle Diagnostic Ground Circuits in the vehicle Diagnostic Connector are damaged or the Connector are functioning and that the cable 1s not rec
40. hicle or to an additional interface adapter required for some vehicles Refer to the Help System for specific information on connecting the interface cable to the vehicle Specific information can be found under the Setup and Configuration Section The location of the connector is different on each vehicle Consult the appropriate service manual for the location of the diagnostic connector Connect the Interface Cable to the Vehicle Diagnostic Connector or adapter after making sure that the connector terminals are not damaged or bent Also please refer to the Cautions Section for important safety information related to the Interface Cable 17 papies Bupj3es iy uoj2es Section 4 Getting Started Using the SmartLink Interface Module The Digital Wrench SmartLink Module 1s the next generation diagnostic interface for Polaris vehicles starting with Model Year 2006 Currently the SmartLink module must be used with vehicles use the CAN Controller Area Network diagnostics y Wrench Smartlink Diagnostic Interface Module Part Nr 01 10005 O Ha Diagnostic cL DRIN Associates POLARIS z Kit Contents The SmartLink kit consists of the SmartLink Module itself the Vehicle Interface Cable for vehicles that use the CAN diagnostic connection new 8 pin diagnostic connector and a standard serial cable to connect to the Digital Wrench PC Wem DSAPN SPXPN SmartLink Kit all three items below 01 20002
41. ing and customer satisfaction Following this process correctly will help ensure better faster diagnosis and fewer come backs You can learn more about this process by taking the ASSERT and Satisfy online training module on the Know the Way Out website but the outline is also presented below for your reference ASSERT is an acronym that stands for e A Ask Collect customer data You will need Machine information VIN mileage ownership history etc Maintenance history Detailed description of condition S See Verify condition and visually inspect Perform walk around Look at machine for obvious causes Determine whether the condition can be verified safely and without damaging the machine Verify the condition Identify any preventative maintenance that could have an effect Identify outstanding service communications Safety Bulletins Service Bulletins or Team Tips that could have an impact on condition S Solve Determine root cause Implement the 31 diagnostic process Illustrate Create a diagram of the affected system Isolate Test to isolate affected components Identify Positively identify the root cause Why did this occur What else might be affected How can this be prevented in the future Note Systems are organized in ASSERT and Satisfy as follows Electrical Includes any component that generates stores distributes controls or co
42. ions senes 27 Sensor Data Screen Keyboard Functions eerte ntes 27 Introduction to ASSERT aud SOUL neuik c pita tax mad Erit pEHAT EH P PEH TERMES 28 The ASSERT Process and ASK Form eeeeeeessssseeeeeeeenen nennen nnn 30 POOLE T UOTE rPPPPpPPpPppgpvpprR 31 Vehicle Selection Screen cc cccccccscaccecccccacceccecceccesccecescasceecescuecescescescascscascaseascs 31 Customer Information Screen aaa saaa aaa saaa aa aaa aaa aaa aaa saaa saaa saaa 32 LronbiCOC SUS MP i S S ane en nee enn 33 Data Wis olay CH iai R aa a aaa 37 Data Chart e S NER 4 Pati Mor SOLES TIL ncanetosim iai i a i MINEURS 42 Dual C Barb and IN TC CS GE CS ee er RII i qund neers eee 43 visuri Didi V asai iai ia i K i t i i I a is 44 Data Trigger Setup Screen DINAaDSHOL Lisu kiniiussistisississkasss iais te sinus Paid eese esu a 45 Special USS MS T PERENNE 47 AVIS n Oni SE A LO Elk stai aa i B a ao 48 Vemde Home TIE passant TET 49 lusu AEE A AT EEE EAE E EA E 50 PS YS a esiste ede ce A pce easing aaa de ie AE E AE 50 Ei DO Iar ii ii ne ee ee a ee a a eee ee 50 e AB Lies ea esee mri Pr PpPpyrprPPPPP Pra 51 LGE DIOE iso ai utut E i IEEE MIENNE UNE MINUM a MEE 51 Important Consideration S esn ee a oi i i S 51 common D ELO JAS e i a a i a a M DM 52 Guided Diagnostics Screen types aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa aaa 32 IVS LE LOS E E Ha necesite D Ne MEMIN
43. ions based on Trouble Codes Setting or a specific sensor value Open the Special Tests Menu Load the ASK Form or return to the current location in the form if it 1s already loaded Open the Vehicle Selection Screen Load or Return to the Customer Information page of the ASK Form Load the Vehicle Home Page Open the Software Configuration Screen Open Digital Wrench Help Exit Digital Wrench 24 Using the Keyboard to Run the Program The Diagnostic Software is designed to be run using a mouse or other pointing device attached to the PC however many of the functions can be accessed using the keyboard as well The following tables describe the keyboard functions on each screen Main Control Panel Keyboard Functions The Function Keys on the keyboard will always function regardless of where you are in the program They can be used to quickly move from one part to another The only exception 1s when the Manual Browser is the active application 1 e the window in front When the Manual Browser is active pressing the function keys may have unexpected results depending on the type of document manual being viewed The ESC Key usually the key in the upper left portion of the keyboard can always be used to close a screen and back up through the application To perform this function Press this Key Read Trouble Codes View the Data Grid F2 uousJM jexibig BUISN 26 uonosee
44. is detected O Wrench POLARIS Smartlink Diagnostic Interface Module Part Nr 01 10005 Diagnostic x Systems Associates M SmartLink Module PU 47468 DSA PN 01 10005 15 Pin Connector for Vehicle Interface Cables c D m T Vehicle Interface Cable PU 47469 DSA PN 01 0004 Connect to Vehicle Diagnostic Connector SmartLink Kit PU 47471 DSA PN 01 20002 19 Flashes Once at Power up papies Dunes iy uoj2es Section 4 Getting Started Using the SmartLink starting with Model Year 2006 Vehicles the SmartLink Module and CAN Vehicle Interface Cable should be used whenever performing diagnostics on the CAN Based Vehicles Sportsman amp Ranger 500 EFI For 2007 vehicles the SmartLink Module is used on all EFI ATV Ranger and CFI Snowmobiles All other existing EFI vehicles use the same diagnostic interface cable as they always have The diagnostic connector location varies for each vehicle Always refer to the Digital Wrench help system for details on finding the connector The SmartLink Module is powered through the vehicle diagnostic connector When the module is first powered up the Status LED will blink once indicating that it is ready At all other times the LED will remain off although future applications may utilize the LED to provide additional information on communications or special test modes If the Status LED blinks rapidly or stays on steady an error has been detected in the
45. l Click Finish After a short time this screen should disappear The initial Setup Launcher program seen in Step 3 may still be on your screen If it is it is safe to close it now Close the Setup Launcher by clicking on the button next to Exit This Program or by clicking on the X in the upper right hand corner of the window 11 Possible Messages and Errors During the Install Process there are several possible error or other messages that may come up These messages are displayed in a window similar to the following Polaris Digital Wrench 3 0 B95 Setup uy The application you are trying to install is running Close it and try again Other messages may come up during the install process if the software cannot be successfully installed or if any of the required Windows components are missing section 4 Getting Started If any error messages are displayed read them carefully and follow any instructions given Additional information on error messages is available in the Troubleshooting section at the end of this manual and in the on line help system at http polaris diagsys com kb 12 Running the Software Once the install process has been completed there will be a new icon on the Desktop Select this icon to run Digital Wrench or by selecting the Astan button selecting Programs from the start menu and then navigating to the program group where the program was installed normal
46. l View the Sensor Data Screen 4 Trouble Code Screen Keyboard Functions To perform this function Press this Key Clear Trouble Codes Del Close the Screen 25 Data Grid Screen Keyboard Functions To perform this function Press this Key Select a Data Item Up Arrow Down Arrow Keys Disable or enable updates of a Data Item Change to the Large Digital Meter Screen Change to the Data Chart Screen Mark a point on the Data Recorder press the Mark Button Stop Data Recording press the Stop Button Start Data Recording press the Go Button Close the Screen Large Meter Screen Keyboard Functions To perform this function Press this Key Switch to the Data Chart Screen Page Down Key Move to the next Data Item in the list M Move to the previous Data Item in the list Left em Key Add a Second Meter DEP Remove the Second Meter Move the Second Meter to the next item in Alt and Right the list Arrow Keys together Move the Second Meter to the previous Alt and Left item in the list Arrow Keys together Section 5 Using Digital Wrench Mark a point on the Data Recorder press the Mark Button Stop Data Recording press the Stop Button Start Data Recording press the Go Button Close the Screen 26 Data Chart Screen Keyboard Functions To perform this function Press this Key Switch to the Large Meter Screen Page Up Key Move to the next Data Item in th
47. ly this would be EFI Diagnostic System and then select the EFI Diagnostic System Entering The Software Serial Number The first time you run the software you will be asked to enter the Software Serial Number A Serial Number is required to use this software Please Enter your 10 digit Serial Number below XXXXXXXX Enter the Software Serial Number from the Serial Number Sticker on the CD Sleeve When a valid serial number has been entered the number will turn Green Select OK to continue 13 papies Dues iy uoj2es Section 4 Getting Started Registering the Software 14 When the EFI Diagnostic System is installed for the first time you are given a 30 day trial period where the software will run without being registered During this period you are able to take advantage of the full functionality of the software but a Reminder Screen appears each time you launch the application to inform you of the number of days remaining in the trial If you do not register the software before the trial period ends it will not function until the Registration Feature Code is entered You have 30 day s left in the trial period After leaving the Reminder Screen the Feature Configuration Screen appears Features Registratio amp POLARIS BSTE3 727C8 CB6CB 3946B Write down the License ID and then go to the Internet Web Site shown on this screen If the PC you are using 1s connected to the Internet
48. measurement from the multimeter and use it to choose the appropriate answer in the answer area The answer area is the place for you to provide your Amer answer to the software Click the number button corresponding to the best answer to the question asked or double click on the answer text itself 54 Question Screen Question e Question Screens are used to provide information to the Diagnostic Procedures which cannot be obtained by direct measurements or other means e There are two components to a Question Screen uouosJM jexibig BUISN iQ uonoee In the Question Area there may be instructions given similar to the Instruction Screen however there will always be a Question asked The answer area is the place for you to provide your answer to the software Question Click the number button corresponding to the best answer to the question asked or double Answer click on the answer text itself Always read the Question carefully before answering to make sure the correct answer 1s provided 55 Section 5 Using Digital Wrench 56 Data Screen Anstruction e Data screens request data from the Engine Controller and use the information returned to make a decision on which path to follow in the Diagnostic Procedure When the Continue Button 1s pressed the Data Value currently displayed 1s used to make the decision e The Interface Cable must be connected
49. ms may also be shown on the Trouble Codes Screen e The information shown will depend on the Vehicle Engine being tested e The Description and Info columns are always present Description The Description Column contains a brief description of the nature of the fault code Status Not Always Displayed Hours Not Always Displayed te Not Always Displayed 34 The Status Column will either show Current or Historic Current indicates that the failure that caused the Trouble Code 1s still present in the Engine Controllers memory also know as a Hard Fault A status of Historic indicates that the conditions that caused the Trouble Code to be set are not currently present in the system Historic Codes are most often caused by broken or loose connectors which cause intermittent connection problems The Hours Column indicates when the Trouble Code set based on Engine Hours Comparing this number to the current Engine Hours gives an indication of how long ago the Trouble Code set The Column indicates how many times the conditions necessary to set the Trouble Code have occurred A 1 in this column indicates that the code has set once and may also indicate that the conditions to set the code are still present A number greater than one indicates that the conditions to set the code have come and gone several times Freeze Frame Trouble Code Not Always Displayed Usually one of the Trouble Codes show
50. n on the Victory Trouble Code Screen will be highlighted with a This Trouble Code is what is known as the Freeze Frame Trouble Code The Freeze Frame Trouble Code is usually the first trouble code that set 1f there are more than one code present and there will be additional information available for this trouble code available under the Freeze Frame Data Button Freeze Frame Data Not Always Displayed 4 Codes Engine Temperature 82 4 Deg F Barometric Pressure 28 3 InHg 5095 RPM uousJM jexibig BUISN iQ uonoee The Button on the bottom of the Trouble Codes Screen can be used to view the Freeze Frame Data of the Freeze Frame Trouble Code The Freeze Frame Data are the values of the main engine sensors at the moment the Freeze Frame Trouble Code was set Pressing the Codes Button will return to display of Trouble 23 Section 5 Using Digital Wrench Trouble Code Information Screen Wrench PTO Full Loud Injector Circuit Faulty Stator Tin Treekle Cade orin d an Opern Cimi or Thori ie reund Combia in detested m the miii PTO Fal Laad l peit s Danima eer Can bee famed kg agl Vwing a laur Fuel Injersor ar FCU Conpertiana fete A Funky Etter ran sion ze irr rode be sel PI ulli sad inecior in n PO igen C od Cupra i Ea PVG Beam banal pesci CR JA Pt Cp Du Volle Hip x PP mum velilapii m 2 Selecting the button next to one of the trouble code descriptions on the Trouble Codes Screen will
51. net Web documents will always be the most current information and there may be more information available Loading the Vehicle Home Page from the Internet requires that there be an Internet connection available on the Digital Wrench PC and in most cases the Home Page will take quite a bit longer to load 49 Section 5 Using Digital Wrench On certain screens the Print Button will print out a report on the default printer When there 1s no information to print selecting the print button will have no effect All the reports will have the Customer Information and Workshop Information included on the printout 1f it has been entered in on the Customer Vehicle and Configuration Screens The Engine Controller information will also be included on the report The Print Button Will set in the engine controller Screen Print Button was selected when the Print Button was selected when the Print Button was selected when the Print Button was selected Vehicle Home Page Print the current document shown in the Information System Window Use with care some documents are very long and many many pages will be printed Help System The Help Button will open the help system when selected The Help System contains the most complete and up to date information on Digital Wrench Although the information in the Help System 1s similar to what 1s 1n this manual always refer to the Help System first Exit Button The Exit Button will
52. nsumes electricity Drive Includes any component used to support internal combustion and distribute that power Chassis Includes steering suspension braking cosmetic items frame track skis wheels and tires etc E Explain Plan and present your solution to the customer Determine the best most cost effective solution Describe your findings and recommendation Get the customer s agreement on the repair R Repair Complete the work Repair or replace affected components Perform appropriate service bulletin repair Complete necessary maintenance with customer approval e T Test Verify the effectiveness of the repair Confirm that the repair maintenance was effective Sign off on work order Satisfy Follow up with the customer to ensure complete satisfaction with your work uousJM jexibig BUISN 26 uonosee Digital Wrench 3 0 supports the ASSERT and Satisfy process in two ways 1 The work order form or case includes many detailed questions you can use to find clues to aid diagnostics This form can also be saved and printed 2 On each vehicle home page for non EFI vehicles you will have access to Illustrations block diagrams of key vehicle systems and a list of tests you can use to Isolate root cause For experienced Digital Wrench users please note the core functionality remains the same The additional new features are designed to make the tool more user fri
53. pLaunch exe but make sure to substitute the drive letter for your CD ROM drive in place of the D if D is not the letter for your particular CD ROM Drive Type Ehe name of a program folder document or Internet resource and Windows will open it Far vau Open D SebtupLaunch exe Cancel Browse 3 Once the setup program has started you will see a window like this Setup Launcher Install EFI Diagnostic oystem Software Install Adobe Acrobat Header Software Install Internet Explorer Software Exit this program The CD contains installation programs for Internet Explorer 6 and Adobe Acrobat Reader 5 01 both of which are required for Polaris Digital Wrench to work properly You can install each of these programs at any time by clicking on its corresponding button Many computers are already equipped with these programs and do not need to be installed from this CD If you are not sure whether you need to install these programs you can refrain from installing them right now The install program will check and let you know if either Internet Explorer or Acrobat Reader needs to be installed Click on the button next to Install EFI Diagnostic System Software to begin the main install process 4 After a short time the setup screen will appear tei Polaris Digital Wrench 3 0 B94 Setup ae POLARIS Welcome to the Polaris Digital Wrench 3 0 694 Setup Wizard This wizard will quide
54. ported Windows 2000 XP Vista Windows 7 e Any computer capable of running Windows 2000 XP Vista or Windows 7 should be able to run Digital Wrench as long as the minimum hardware requirements are met for the version of Windows used NOTE for Windows 2000 XP Vista and Windows 7 You must be logged into the system with Administrator Rights to install the Diagnostic Software On Windows Vista and Windows 7 always install the software using Run as Administrator to start the installer If you are unsure if you have Administrator Rights please verify this before proceeding with the install procedure THERE ARE VERY FEW USB TO SERIAL ADAPTERS THAT WILL FUNCTION PROPERLY WITH THE DIAGNOSTIC SOFTWARE If you have a laptop PC without a Serial Port refer to the Digital Wrench Website for information on which USB to Serial adapters will function with this software This section contains information on safety that must be followed to avoid damage to Polaris Digital Wrench or serious injury or death to the operator Do not skip over this section Read it carefully and thoroughly Before Using Digital Wrench instructions before using Digital Wrench Application Always make sure the Interface Cable and Diagnostic Connector terminals are clean and in good condition before connecting the cable Verify that the vehicle battery is fully charged and in good condition before attempting to use the Diagnostic Software Low battery voltag
55. r to connect the vehicle interface cable While there are many USB to Serial and PCMCIA serial Port adapters that will function properly with the diagnostic software there is a much larger number of devices that will not function properly or at all Most low priced adapters are not capable of the data transfer rate baud rate necessary to communicate with the vehicle on board computer Before purchasing an adapter check on the Digital Wrench Support Website available in the help menu under Digital Wrench Home Page for the latest list of adapters that have been tested amp known to work properly with the software Serial Port Problems with low power Laptop Computers Many new low power or extended battery life laptop computers are equipped with serial ports that do not perform well enough to communicate with the vehicle on board computer while running on battery power In addition there are some laptops that still exhibit communications problems even when connected to AC Power Often these communication problems can be reduced or eliminated by modifying the configuration of the serial port Further information and details on setting the serial port configuration are available on the Digital Wrench Support Website available 1n the help menu under Digital Wrench Home Page Connecting to the Vehicle The vehicle end of the Communications Interface Cable has a 4 pin connector which connects either directly to the ve
56. rt format Time in seconds is shown horizontally on the chart and the data value is shown vertically The chart shows 10 seconds worth of information and 30 seconds total can be stored in the Record Playback controls The red marks on the graph show the actual data points at the time they were received from Engine Controller The following buttons and controls are available on this screen What This Button Does The Next Data Item Button will change the chart display to the next data item 1n the Data Grid List moves to the next item down the list The Previous Data Item Button will change the chart display to the previous data item in the Data Grid List moves to the next item up the list The Plus Button can be used to add a second data chart to the screen When this button is pressed a list of available data items will be displayed in the center of the screen Select the data item for the second chart by either clicking on the data item name pressing the number next to the item or using the arrow keys on the keyboard to move through the list Often there are more items on the list than are displayed at one time Use the arrow keys to move to the bottom of the list to see any additional items The Meter Button will switch the display from the Data Chart Screen to a single meter of the current data item 4 Youd jexibig BUISN 26 uonosee Data Meter Screen and Meters The Data Meter Screen displa
57. rt or meter can be added to the screen by selecting the r 1 Plus Button T on the chart or meter screen and selecting a second data item from the list shown below 43 Section 5 Using Digital Wrench sensor Data Display Display Intake Air Temperature Deg F Co o DOR y Engine Temperatura TPS Low Resolution DKS 14 68 6 The Sensor Data Display Screen shows the values from the main Engine Control System Sensors The content of this screen depends on the vehicle being tested Frontier Snowmobile Throttle Position Engine Speed Engine Temperature and Oxygen Sensor Volts are displayed as large digital meters Sportsman ATV Intake Air Temperature Throttle Position Engine Speed and Engine Temperature are displayed Victory Motorcycles Throttle Position Engine Temperature Barometric Pressure and Air Temperature Sensors are displayed Direct Injected Watercraft Throttle Position Engine Temperature Alternator Voltage and Air Temperature Sensors are displayed MSX 4 Stroke Watercraft Battery Voltage Throttle Position Oxygen Sensor Voltage and Engine Temperature Sensors are displayed Fusion IQ RMK Throttle Position Engine Temperature Barometric Pressure and Air Temperature Sensors are displayed The Data Recording Controls are also present on this screen Refer to the Data Recording Control section in this chapter for information on how to us
58. rt time to evaluate the data it receives from the Engine Controller If there is a problem receiving this data the Waiting for Communications Screen will appear see the Troubleshooting section for more information The cause of the Communications Problem will have to be resolved before the Diagnostic Procedure can continue e A visible Trouble Code Screen will give you instructions about what if anything you need to do e The most common use for a visible Trouble Code Screen 1s a Wiggle Test The Wiggle Test 1s used to locate intermittent wiring faults by continuously monitoring for Trouble Codes while the wiring harness connectors sensors etc are Wiggled moved or tapped If no problems are detected pressing the Continue button will proceed to the next step in the procedure 57 Section 5 Using Digital Wrench Conclusion Screen Conclusion e The Conclusion Screen will either display a Final Diagnosis and suggested remedies to the problem or a list of potential problems and additional test procedures to follow e Diagnostic Conclusion Screens can be printed by selecting the Print Button on the Main Control Panel 58 Troubleshooting Waiting for Communications e The Waiting for Communications Screen will appear 1f the Guided Diagnostics System 1s attempting to retrieve information from the Engine Controller and there is a Communications Problem When a few seconds have elapsed without a response from th
59. s to the ECU has been interrupted Initializing communications usually takes from 2 to 4 seconds This message will show briefly while the system is starting up or when the ECU is not responding This message indicates that the interface cable is not connected to the Diagnostic Connector the ignition 1s off or there is no power to the connector This will also come up if the cable is connected to a different port than the one selected on the Configuration Screen This message indicates that communications to the Engine Controller has been initiated and data is available for display This message indicates that the software has detected an unknown unsupported Engine Controller or that the ECU Identification indicates that it is from a vehicle other than the one selected on the Vehicle Selection Screen This message indicates that the cable 1s connected to a vehicle but there 1s no response to requests for data This can be caused by damaged connections in the cable or vehicle A defective Vehicle ECU can also cause this message to come up 23 YoudlM jexiBig BUISN 26 uonosee Section 5 Using Digital Wrench The Main Control Panel Buttons What this button does Key Display Trouble Codes Trouble Code Information and Wiring Diagrams Display Sensor Data and Parameters in a grid large meters or chart format Display data from the primary engine system sensors Set up data capturing funct
60. spected use Scandisk a utility program that is part of Windows or another Hard Disk utility to check for and possibly repair any errors on the disk Internet Explorer and Acrobat Reader Install Problems Problems that occur with installation of Microsoft Internet Explorer 6 or Adobe Acrobat Reader and solutions to those problems are available at the Internet sites of Microsoft www microsoft com or Adobe Systems www adobe com Diagnostic System Install Problems The following issues should be considered when problems occur while installing the software e Always install Internet Explorer 6 and Acrobat Reader before installing Digital Wrench Software On older versions of Windows the install process will generate an error if Internet Explorer has not been installed e Ifthe system needs to be rebooted during the install process do not select the reboot later option Always reboot the PC before continuing on to the next step With older PC s this can be long and time consuming process but once it 1s done updates to Digital Wrench will go very quickly e On Windows NT 2000 and XP Systems always make sure that the User Name you have logged in as has Administrator Rights Otherwise the install will fail Communication Problems There are many possible causes of communications problems with the vehicle Often they are very simple to remedy Commstatus No Cable or Power This message is
61. stration Screen Refer to the Software Help System for specific information about Feature Configuration amp Registration 47 Help Balloons Sta rt Up Help Kohler 1100112384 Polaris 0983 661549 eee ees SmarLink Module The System Configuration Screen can be used to set the Units of Measure Workshop Information and Communications Port setting What it Does Select the desired units of measure using the US or Units of Metric buttons The setting chosen here will be the Measure default for the system and will be used each time the system 1s started Workshop Enter the Workshop Name and Address in the boxes Information provided This information is used on printed reports select the communications port number where the Interface Cable 1s connected to the computer Click on the currently displayed Comm port if you want to select a different one All the Communications Ports available for use will be COM Port shown in this list NOTE If the port you have the cable connected to is not listed it is likely that another software Section 5 Using Digital Wrench application using this port Refer to the Troubleshooting Section for more information Help balloons come up when the mouse pointer 1s left Help ae Balloons sitting over one of the software buttons They can be turned on and off here Serial Displays the Serial Number s for this license of the Numbers diagnostic software Start up Turns
62. uration screen OK This means that the Comm Port that Digital Wrench has been configured to use 1s no longer available This situation can occur when other applications that use serial communications ports are installed after Digital Wrench has been installed Make sure there are no other applications running which are using the same communications port as Digital Wrench Note If there is an Icon like M6 on the screen near the system clock then the Palm Pilot HotSync Manager is running and may be using the same port as the Diagnostic Software Close the Palm Pilot software and try again System Configuration Invalid 64 System Configuration is Invalid Please Reinstall This error can occur when the install process was not completed properly or some other situation caused the program installation to fail Try uninstalling and re installing the application again see the uninstall section on page 15 If this error continues to come up contact technical support
63. ve as an introduction to the chart e After you have read the screen and performed the task if necessary click the Done Continue Button to proceed to the next step Youd jexiBig BUISN 26 uonosee Always follow any instructions given completely and exactly Skipping a step or ignoring an instruction is almost guaranteed to produce incorrect diagnostic results 53 Section 5 Using Digital Wrench Measurement Screen Measurement e Measurement Screens aid in taking a measurement with a multimeter The measurement data 1s used in making the diagnosis After taking the Measurement answer the Question about the measurement e Always double check the connections and measurement before providing the answer The measurement area displays information about the measurement to be taken such as the Measurement recommended multimeter settings There may also be a short explanation of what is being measured or why The connection area tells you where to hookup the Connection two leads of the multimeter Pin numbers and wire colors are often mentioned here The connection pictures if available give you a real life image of the involved wiring or the meter connection to be made If there is no Connection Connection Picture Picture available the button will be gray and nothing will happen if you click on it The question area asks a question about the Onesion measurement result Note the
64. ys a single data item as a large digital meter The following buttons and controls are available on this screen Section 5 Using Digital Wrench The Next Data Item Button will change the meter display to the next data item 1n the Data Grid List moves to the next item down the list The Previous Data Item Button will change the meter display to the previous data item in the Data Grid List moves to the next item up the list The Plus Button can be used to add a second meter to the screen When this button is pressed a list of available data items will be displayed in the center of the screen Select the data item for the second meter by either clicking on the data item name pressing the number next to the item or using the arrow keys on the keyboard to move through the list Often there are more items on the list than are displayed at one time Use the arrow keys to move to the bottom of the list to see any additional items The Chart Button will switch the display from the Meter Screen to a single chart of the current data item 42 Dual Chart and Meter Screens SE lt gt POLARIS and Meters YoUudlM jexibig BUISN 16 uonosee Dual Meter Screen The Dual Data Chart and Meter Screens are identical to the Data Chart and Meter Screens except that two half height charts or meters are shown on the screen and there are Next Data and Previous Data buttons for each one of the charts A second cha

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