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9916575 1998-1999 Big Boss 6x6 Service Manual Chapter

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1. Ge POLARIS 10 29 SALES INC ELECTRICAL ALL WHEEL DRIVE SYSTEM All Wheel Drive Activation In Reverse For AWD in reverse gear the override button must be pushed in addition to selecting All Wheel Drive Power is delivered through the transmission switch the override button the AWD button and then to the front wheel coils ALL WHEEL DRIVE AWD TESTING The All Wheel Drive AWD system is activated when battery voltage is supplied to the front wheel coils Always check battery voltage when an AWD problem is encountered Charge battery and check charging system if nec essary If only one wheel hub does not engage test wheel coil resistance and inspect wheel coil wires for damage Check for a mechanical problem if resistance measurements are within specifications 1 Remove front cover to gain access to harness connectors 2 Turn ignition key on and shift transmission to high gear 3 Select AWD with AWD button 4 Check for battery voltage across Gray and Brown wires from backside of hub coil harness connector NOTE If power is present and bulb is good All Wheel Drive lamp will be lit If no voltage is present on the Gray wire at harness connector check the AWD switch and transmission gear position switch If voltage is present on the Gray White wires at harness connector transmission gear posi tion switch is functioning properly Refer to AWD and Transmission Gear Position Switch Testing this section If voltage is
2. Ignition Coil Secondary Winding Check coil mount for good ground to engine 0 292 Magnetic Switch Ignition Exciter Coils Battery Charging Coils Refer to wiring diagrams for Flywheel and specified stator coil resistance Ring Gear Casting Refer to page 10 7 for identification 10 8 Gp POLARIS SALES INC ELECTRICAL IGNITION SYSTEM Whenever troubleshooting an electrical problem you should first check all terminal connections to be sure they are clean and tight Also be sure that colors match when wires are connected Use the following pages as a guide for troubleshooting The resistance values are also given on the specification pages Condition No Spark or intermittent spark Replace Spark Plug Test the ignition switch engine stop switch and speed limiter circuit for Yes shorts to ground Check connectors for moisture wire color matching or corrosion Disconnect the black wire at the CDI module to isolate the ignition from the kill system Does it have spark No Disconnect the exciter coil and pulse coil connec tor from the CDI module Measure the resistance of the exciter coil and pulse coil Refer to the ex ploded view on page 10 8 or the wiring schematic for meter connections and specifications No Compare results to the specifications on the ex ploded views Are all within specifications Inspect connectors wiring and grounds to the component in question Repl
3. and Yellow at the connector R W and from the headlamp high beam harness Y and low beam harness Test the switch con nections and compare to the chart Continuity NEUTRAL LIGHT CIRCUIT OPERATION Power is supplied to the transmission switch from the Red White wire when the key is on When neutral is se lected power flows through the switch to the Green White wire through the lamp and to ground via the Brown wire If the light is not on when neutral is selected check the bulb If the bulb is good check the wiring transmission switch and lamp socket ground path SALES INC ELECTRICAL ELECTRONIC THROTTLE CONTROL ETC SWITCH The Electronic Throttle Control ETC system is designed to limit the engine RPM of an ATV in the event of a mechanical problem with the throttle mechanism The ETC switch is mounted independently of the throttle actua tor lever inside the throttle block assembly This is anormally closed switch and is held in the open position micro switch button depressed by throttle cable tension The switch is open in normal operation regardless of throttle lever position In the event of a mechanical problem in the throttle mechanism cable tension is lost the switch contacts close switch pin is released delivering battery voltage to the Speed Limiter module via the white wire Battery voltage on the white wire will cause the ignition system to misfire at the ETC Limit listed on page 10 27 Test
4. Eeer EE PN 8712100 or PN 8712500 ELECTRICAL SERVICE NOTES Keep the following notes in mind when diagnosing an electrical problem eRefer to wiring diagram for stator and electrical component resistance specifications eWhen measuring resistance of a component that has a low resistance value under10 Ohms remem ber to subtract meter lead resistance from the reading Connect the leads together and record the resistance The resistance of the component is equal to tested value minus the lead resistance 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 for more information eVoltage amperage and resistance values included in this manual are obtained with a Fluke 73 Digital Multimeter or a Tektronix DMM155 Both of these meters are acceptable for use when diagnosing electrical problems Readings obtained with other meters may differ ePay attention to the prefix on the multimeter reading K M etc and the position of the decimal point eFor resistance readings isolate the component to be tested Disconnect it from the wiring harness or power supply G5 POLARIS 10 1 SALES INC ELECTRICAL HEADLIGHT ADJUSTMENT The high beam headlight can be adjusted to any position desired by turning the four screws at the outer corners of the lamp housing Use the following proce
5. groove 7 Inspect permanent magnets in starter housing Make sure they are not cracked or separated from housing CAUTION Use care when handling starter housing Do not drop or strike the housing as magnet damage is possible If magnets are damaged starter must be replaced SALES INC ELECTRICAL STARTER DRIVE Pinion Gear Anti Kick out Shoe Garter Spring Replacement If the garter spring is damaged the overrun clutch may fail to return properly The replacement spring is PN 7042039 Use either of the following methods to remove and install a new garter spring Polaris Premium Starter Drive Grease PN 2871460 1 Screw the overrun clutch out to the engaged position on the pinion shaft assembly Use a small piece of wire with the end bent in a hook and pick the old spring out of its channel Slide it off the end of the shaft Slide the new spring over the overrun clutch and into the spring groove Make sure that the spring is positioned between the shoe alignment pins and the back flange of the anti kick out shoes Remove the lock ring end washer spring retainers and clutch return spring Screw the overrun clutch off the end of the pinion shaft Remove the old spring and install a new one Lightly grease the pinion shaft and reinstall the clutch spring retainers end washer and lock ring in the reverse order Make sure the end washer is positioned properly so that it will hold the lock ring i
6. present eDisconnect Gray and Brown wheel wires at harness connector and test resistance across the Gray and Brown wires There should be 25 30 of resistance eTest Gray wire to ground on strut casting It should be an open circuit co Move wheel coil wiring harness while performing the tests to check for an intermittent open or short AWD Wheel Coil Resistance Gray to Brown 25 309 No continuity to ground on strut casting eRepair wiring harness or replace wheel coil if necessary NO AWD IN REVERSE If AWD functions properly in forward but not in reverse perform the following tests NOTE Override button must be pushed for AWD in reverse 1 Turn ignition key on and shift transmission to reverse 2 If reverse lamp is on the gear position switch is functioning properly If reverse lamp is off not illuminated check the bulb and test gear position switch and related wiring 3 Check for battery voltage on Purple wire in left hand switch wire harness leave connector connected If battery voltage is present 4 Press the override button AWD light should be lit If not check for voltage on Gray White wire at right hand control eCheck override switch and related wiring if voltage is not present on Gray White wire s If the entire AWD circuit tests correctly inspect the wheel hubs for a mechanical problem ELECTRICAL COOLANT TEMPERATURE SENSOR TEST HOT LIGHT With the ignition switch and engine stop switch ON po
7. CHAPTER 10 ELECTRICAL Special TOO Acs stele Ret Lut eQ amuyu Ds 10 1 Headlamp Service 1998 99 10 2 10 3 Indicator Lamp Service 10 4 Timing Check Procedure 10 5 Typical Ignition Timing Curve 10 6 Flywheel Identification 10 7 250 Watt Alternator Exploded View 10 8 Ignition System Testing 10 9 10 10 Ignition System Troubleshooting 10 11 Battery Service 10 12 10 15 Charging System Testing 10 16 10 18 Starter System Troubleshooting 10 19 Starter System Testing 10 20 Starter Motor Service 10 21 10 25 Starter Drive 10 26 Speed Limiter System Troubleshooting 10 27 10 29 AWD Testing Siva dee kuqa Wty ahi i 10 30 Coolant Sensor Tests 10 31 Fan Control Circuit Operation 10 32 Fan Motor Current Draw Test 10 33 Electronic Throttle Control System Operation 10 34 Wiring Diagrams 10 35 10 36 ELECTRICAL SPECIAL TOOLS Fluke 73 Multitester or Tektronix DMM 155 PN 2870659 Strobe Timing Light PN 2870630 Hydrometer 0 0 eee a a A S usa PN 2870836
8. HARGING SYSTEM BREAK EVEN TEST CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running CAUTION Never use the electric starter with the ammeter connected or damage to the meter or meter fuse may result Do not run test for extended period of time Do not run test with high amperage accessories The break even point of the charging system is the point at which the alternator overcomes all system loads lights etc and begins to charge the battery Depending on battery condition and system load the break even point may vary slightly The battery should be fully charged before performing this test Connect an ammeter set to DC amps in series be tween the negative battery cable and terminal Connect a tachometer according to manufacturer s in structions eWith engine off and the key and kill switch in the ON position the ammeter should read negative amps battery discharge Reverse meter leads if a positive reading is indicated Shift transmission into neutral Start engine with recoil only elncrease engine RPM while observing ammeter and Do not use electric start Current Drain Inspection eNote RPM at which the battery starts to charge am meter indication is positive eWith lights and other electrical load off this should oc cur at approximately 1500 RPM or lower Turn the lights on and lock parking brake to keep brake light on Repeat test observing ammeter
9. T HANDLEBAR KZ l BRN SPEED LIMITER BEHIND OIL TANK L RW W BLI SALES INC
10. Timing Pointer 30 28 EHS50PL Stator Adjustment 1 Remove the magneto housing 2 Remove the flywheel 3 Loosen the stator plate screws and adjust the stator plate position NOTE Moving the stator plate clockwise retards delays the ignition timing Moving the plate counterclockwise advances it Gp POLARIS 10 5 SALES INC ELECTRICAL TYPICAL IGNITION TIMING CURVE Actual advance point may vary by several hundred RPM either above or below 3500 Use the point of maximum advance when checking ignition timing IGNITION TIMING DEGREES B T D C 10 6 MAXIMUM ADVANCE POINT va 0 1000 2500 3000 3500 4000 4500 5000 5500 6000 Gp POLARIS SALES INC ELECTRICAL FLYWHEEL IDENTIFICATION Flywheel Identification Stamp Location The flywheel can be identified by the stamp mark in location A or B Refer to I D location in chart below Do not use the cast mark to determine flywheel application Engine Application Type Cast Stamp Comment Flywheel I D Stamp EES SALES INC ELECTRICAL COMPONENTS OF EHS50PL 250 WATT ALTERNATOR NOTE CDI boxes may look the same but have different internal circuitry Be sure to always use the correct CDI box part number Ignition Coil Primary Winding Resistor Ignition Kill SS gnition Ki Wire Meter Black 3 Wire 39 7 200 W 8 wires 250 W 2 Wires s Pulse Coil Trigger Air Gap 016 040 4 1 0 mm
11. URPLE NO SWITCH NORMALLY OPEN BLU BLUE GRY GRAY 20 A OR ORANGE CIRCUIT Ve St VELLOW BREAKER S FRONT OF W WHITE CLOSED SHIFTER BATTERY RUN gc RUN SWITCH je WO COLO NC S KSE WIRES A r Ge Sun lc N HONN WITH SM l BATTERY EE D R COLORS OPEN OPEN XAMPL RUN RUN t WITH YELLOW KEY OF F RUN GRY W RACE SWITCH SWITCH LEFT OVERRIDE SWITCH HANDLEBAR LEFT HANDLEBAR r CLOSE ON THROTTLE ETC SWITCH CABLE SLACK EE 5 T IN THROTTLE PUR HOUS ING REVERSE LR44 LAMP AE ia inate BLK LOCATED BEHIND OIL TANK CDI T REVERSE SPEED LIMITER BESIDE IGNITION COIL Q O STATO ATTERY YA oc gt 6 i RPM Signal BPM Signal Gray Orange Y R p Gry Or Reverse Gear Signal Bik Engine Stop Si SALES INC POLARIS lt SE 10 28 ELECTRICAL REVERSE SPEED LIMIT SYSTEM APPLY PARKING BRAKE START ENGINE SHIFT TO REVERSE GEAR NO REVERSE SPEED LIMIT LR44 Limit Module MEASURE DC VOLTS ON R W WIRE AT LR44 MOD INSPECT R W WIRE CIR ULE TO GROUND CUIT TO DETERMINE CAUSE 12 VOLTS DC MEASURE DC VOLTS ON GRY OR WIRE AT LR44 MODULE TO GROUND N TEST GEAR POSITION INDICATOR SWITCH 12 VOLTS DC MEASURE AC VOLTS ON Y R WIRE AT LR44 MOD ULE TO GROUND N TEST REGULATOR AND CHARGING SYSTEM 3V 9V AC AT IDLE DISCONNECT BLACK WIRE FROM LR44 MOD ULE AND CONNECT TO GROUND ENGINE STOP TEST WIRING TEST CDI BLACK WIRE
12. Using a digital multitester measure the resistance between each of the commutator segments The reading should be 3 ohms or less 4 Measure the resistance between each commutator segment and the armature shaft The reading should be infinite no continuity 5 Check commutator bars for discoloration Bars discolored in pairs indicate shorted coils requiring replacement of the starter motor 6 Place armature in a growler Turn growler on and position a hacksaw blade or feeler gauge lengthwise 1 8 3 cm above armature coil laminates Rotate armature 360 If hacksaw blade is drawn to armature on any pole the armature is shorted and must be replaced ELECTRICAL STARTER ASSEMBLY 1 Place armature in field magnet casing 2 Place shims on drive end of armature shaft with phenolic washer outermost on shaft Engage tabs of stationary washer in drive end housing holding it in place with a light film of grease 3 Install case sealing O Ring Make sure O Ring is in good condition and not twisted on the case Lubricate needle bearing and oil seal with a light film of grease and install housing aligning marks 4 Install O Ring on other end of field magnet casing Make sure it is in good condition and not twisted on the case 5 Align casing marks and install housing pushing back brushes while installing shaft in bushing 6 Reinstall starter motor housing bolts Make sure O Rings are in good condition and seated in
13. a full charge condition in the OCV test and the specific gravity 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 hook a multitester to the battery in the same manner as was done in the OCV test The reading should be 12 6 volts or greater Engage the electric starter and view the registered battery voltage while cranking the engine Continue the test for 15 seconds During this cranking period the observed voltage should not drop below 9 5 volts If the beginning voltage is 12 6 or higher and the cranking voltage drops below 9 5 volts during the test replace the battery 10 14 G POLARIS SALES INC ELECTRICAL OFF SEASON STORAGE To prevent battery damage during extended periods of non use the following basic battery maintenance items must be performed Remove the battery from the machine and wash the case and battery tray with a mild solution of baking soda and water Rinse with lots of fresh water after cleaning NOTE Do not get any of the baking soda into the battery or the acid will be neutralized eUsing a wire brush or knife remove any corrosion from the cables and terminals eMake sure that the electrolyte is at the proper level Add distilled water if necessary Charge at a rate no greater than 1 10 of the battery s amp hr capacity un
14. ace the compo nent if a wiring problem cannot be found Yes Check coil ground connection between engine and coil Clean coil mounting area mount using an ohmmeter The coil mount should No Repair ground wire connections have good continuity to ground on the engine 0 2 Q Disconnect and check the secondary coil Resis tance values should be Primary Side Primary Wire Tab to Ground on coil mount or engine 3 to 6 Ohms Secondary Side High Tension Wire to engine ground Cap installed 11 3000 No Replace the ignition coil Cap removed 63009 Are these values within specs If all of the above tests are within specifications and all grounds connections and wire color coding have been inspected perform voltage output tests on following page or replace the CDI module Ge POLARIS 10 9 SALES INC ELECTRICAL CRANKING OUTPUT TEST WITH PEAK READING VOLTMETER The following peak voltage tests will measure the amount of output directly from each component A peak reading voltmeter must be used to perform the tests A variety of peak reading adaptors are commercially available for use with the Fluke 73 Digital Multitester Tektronix DMM155 and other digital VOMs which will allow peak volt age tests to be performed accurately Follow the directions provided with the adaptor All measurements are indicated in DC Volts Readings obtained without a peak reading adaptor will be significantly different Disconnect t
15. and tachometer With lights on charging should occur at or below 2000 RPM SALES INC ELECTRICAL ALTERNATOR OUTPUT TEST AC AMP This test measures AC amperage from the alternator eMaximum alternator output will be indicated on the meter It is not necessary to increase engine RPM above idle Place the red lead on the tester in the 10A jack Turn the selector dial to the AC amps A position Connect the meter leads to the Yellow and Yellow Red wires leading from the alternator eStart the engine and let it idle Reading should be a minimum of 7A at idle CAUTION This test simulates a full load on the alter nator Do not perform this test longer than required to obtain a reading or the alternator stator windings may overheat 10 15 seconds is acceptable To Calculate Available Alternator Output Alternator Current Output Minimum of 7 AC Amps 250W 20 8 Amps 12V ER Current in Amps P Power in Watts E Electromotive Force Volts 1018 7 PGLARIS SALES INC ELECTRICAL STARTER SYSTEM TROUBLESHOOTING Starter Motor Does Not Turn eBattery discharged low specific gravity eLoose or faulty battery cables or corroded connections see Voltage Drop Tests eRelated wiring loose disconnected or corroded ePoor ground connections at battery cable starter motor or starter solenoid see Voltage Drop Tests eFaulty starter button Faulty ignition switch Do other systems fun
16. attery gases could accumulate and cause an explosion Vent should be routed away from frame and body to prevent contact with electrolyte Avoid skin contact with battery electrolyte severe burns could result If electrolyte contacts the vehicle frame corrosion will occur 4 Route cables so they are tucked away in front and behind battery 5 Reinstall battery cover and holder strap po not start the engine with the battery disconnected Vehicle lamps will burn out if battery is disconnected during vehicle operation Also the reverse speed limiter can be damaged BATTERY TESTING Whenever a service complaint is related to either the starting or charging systems the battery should be checked first Following are three tests which can easily be made on a battery to determine its condition OCV Test Specific Gravity Test and Load Test OCV OPEN CIRCUIT VOLTAGE TEST Battery voltage should be checked with a digital multitester Readings of 12 6 or less require further battery testing and charging See charts and Load Test on page 10 14 NOTE Lead acid batteries should be kept at or near a full charge as possible Electrolyte level should be kept between the low and full marks If the battery is stored or used in a partially charged condition or with low electrolyte levels hard crystal sulfation will form on the plates reducing the efficiency and service life of the battery SALES INC ELECTRICAL SPECIFIC GRAVITY TEST Atoolsuc
17. cable terminal and brush housing Make sure the brush is not touching the case The reading should be infinite 2 Remove nut flat washer large phenolic washer two small phenolic washers and O Ring from brush terminal Inspect the O Ring and replace if damaged 3 Remove brush plate and brushes Measure length of brushes and replace if worn past the service limit Replace springs if they are discolored or have inadequate tension 4 Inspect surface of commutator for wear or discoloration See steps 3 6 of armature testing on page 10 24 Brush Length 5 Install a new carbon brush assembly in the brush housing NOTE Be sure that the terminal bolt insulating washer is properly seated in the housing and the tab on the brush plate engages the notch in the brush plate housing Brush Length Service Limit 5 16 8 cm SALES INC ELECTRICAL BRUSH INSPECTION REPLACEMENT CONT 6 Place a wrap of electrical tape on the threads of the terminal bolt to prevent O Ring damage during reinstallation 7 Install the O Ring over the bolt Make sure the O ring is fully seated 8 Remove the electrical tape and reinstall the two small phenolic washers the large phenolic washer flat washer and nut SALES INC ELECTRICAL ARMATURE TESTING 1 Remove armature from starter casing Note order of shims on drive end for reassembly 2 Inspect surface of commutator Replace if excessively worn or damaged 3
18. ction eFaulty starter solenoid or starter motor eEngine problem seized or binding Can engine be rotated easily with recoil starter Starter Motor Turns Over Slowly eBattery discharged low specific gravity eExcessive circuit resistance poor connections see Voltage Drop Test below eEngine problem seized or binding Can engine be rotated easily with recoil starter eFaulty or worn brushes in starter motor eAutomatic compression release inoperative Starter Motor Turns Engine Does Not Rotate eFaulty starter drive eFaulty starter drive gears or starter motor gear eFaulty flywheel gear or loose flywheel VOLTAGE DROP TEST 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 1 VDC per 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 next page to perform voltage drop tests on the starter system Voltage should not exceed 1 DC volts per connection SALES INC ELECTRICAL STARTER SYSTEM Condition Starter fails to turn motor NOTE Make sure engine crankshaft is free to turn before proceeding with dynamic testing of starter system A digital multitester must be used for this
19. dure 1 Place the vehicle on a level surface with the headlight approximately 25 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall 3 Shift transmission to neutral start engine and turn headlight switch to high beam 4 Observe headlight aim The most intense part of the headlight beam should be aimed 2 5 1 cm below the mark placed on the wallinstep 2 NOTE Rider weight must be included on the seat For machines with separate low beam lights the drop should be 8 20 3 cm in 25 5 Adjust screws at outer corners of lamp housing to achieve proper aim HEADLIGHT LAMP REPLACEMENT A WARNING Due to the nature of ATVs and where they are ridden headlight lenses become dirty Frequent washing is necessary to maintain lighting quality Riding with poor lighting can result in severe injury or death 1 Remove the seat 2 Remove the plastic panel surrounding the upper portion of the gas tank by first removing the gas tank cap 3 Remove the Phillips screws on either side of the panel at the junction of this panel the lower panels and the rear of the front fenders 4 Remove the Phillips screws on either side of the rear of the upper panel which were revealed by the removal of the seat 5 Remove the door on the front of the ATV covering the radiator cap by turning the fastener one quarter turn 6 Disengage the tabs atthe fro
20. h as a Battery Hydrometer PN 2870836 can be used to measure electrolyte strength or specific gravity As the battery goes through the charge discharge cycle the electrolyte goes from a heavy more acidic state at full charge to a light more water state when discharged The hydrometer can measure state of charge and differences between cells in a multi cell battery Readings of 1 270 or greater should be observed in a fully charged battery Differences of more than 025 between the lowest and highest cell readings indicate a need to replace the battery OPEN CIRCUIT VOLTAGE State of Conventional YuMicron charge Lead acid Type 100 Charged 12 70V 75 Charged 12 50V 50 Charged i 12 20V 25 Charged 12 0V 0 Charged less than 11 80V less than 11 9V Detail A SPECIFIC GRAVITY State of Conventional YuMicron L charge lead acid Type 100 Charged 1 265 1 275 75 Charged 1 210 1 225 50 Charged 1 160 1 175 25 Charged 1 120 1 135 0 Charged less than 1 100 less than 1 115 At 80 F NOTE Subtract 01 from the specific gravity reading at 40 F Polaris PN 2870876 1 1 1 15 1 2 1 2 LOAD TEST CAUTION Remove spark plug high tension leads and connect securely to engine ground before proceeding NOTE This test can only be performed on machines with electric starters This test cannot be performed with an engine or starting system that is not working properly A battery may indicate
21. he stator connectors from the CDI module Test output from exciter coil pulse trigger coil and compare to the chart The following measurements are obtained when cranking the engine with the electric start er spark plug installed The starter system must be in good condition and the battery fully charged 250 Watt 4 Stroke Coil Connect Meter Reading Wires To With Peak Reading Volt meter Black Red and Red 140 DCV Black Red and Green 140 DCV Green and Red 5 DCV Pulse Trigger White Red and White 2 5 DCV CDI OUTPUT TEST USING PEAK READING ADAPTOR Re connect all CDI wires to stator wires Disconnect CDI module wire from ignition coil primary terminal Connect one meter lead to engine ground and the other to the ignition coil primary wire leading from the CDI module Crank engine and check output of CDI wire to coil 180 DCV Reconnect coil wire to CDI Output w Peak output tester 130 DCV Average Output w Digital Voltmeter 20 DCV 1010 PGLARIS SALES INC ELECTRICAL IGNITION SYSTEM TROUBLESHOOTING No Spark Weak or Intermittent Spark eSpark plug gap incorrect Fouled spark plug eFaulty spark plug cap or poor connection to high tension lead eRelated wiring loose disconnected shorted or corroded eEngine Stop switch or ignition switch faulty eETC switch misadjusted or faulty e Terminal board or connections wet corroded ePoor ignition coil ground e g coil mount loose or corroded eFaul
22. mum service life and performance from a new battery perform the following steps NOTE Do not service the battery unless it will be put into regular service within 30 days After initial service add only distilled water to the battery Never add electrolyte after a battery has been in service NOTE New Battery Battery must be fully charged before use or battery life will be significantly reduced 10 30 of batterys full potential Remove vent plug from vent fitting Fill battery with electrolyte to upper level marks on case Set battery aside and allow it to cool and stabilize for 30 minutes P eo N Add electrolyte to bring level back to upper level mark on case NOTE This is the last time that electrolyte should be added If the level becomes low after this point add only distilled water 5 Charge battery at 1 10 of its amp hour rating Examples 1 10 of 9 amp battery 9 amp 1 10 of 14 amp battery 1 4 amp 1 10 of 18 amp battery 1 8 amp recommended charging rates 6 Check specific gravity of each cell with a hydrometer to assure each has a reading of 1 270 or higher BATTERY TERMINALS TERMINAL BOLTS Use Polaris corrosion resistant dielectric grease PN 2871027 on battery bolts See Battery Installation on page 10 13 1012 PGLARIS SALES INC ELECTRICAL BATTERY INSPECTION REMOVAL The battery is located under the left rear fender Inspect the battery fluid level When the battery fluid near
23. n its groove Starter Solenoid Bench Test It is difficult to test the high amp side of the solenoid accurately on the bench The only test which can be done on the bench is the pull in coil resistance The reading should be 3 4 ohms 10 26 Starter Motor Exploded View Washer Set Rear Brkt A Carbon ear Brkt Assy Brush Set a Wen 00000 Weight Spring Return Spring G POLARIS SALES INC ELECTRICAL Speed Limiter see Module LR ID Number LIMITER SPECIFICATIONS E NOTE The part number is printed on some late model D LR modules Whenever possible use part number to identify the module Modules may have same LR SECH LD number with different part numbers terminals and Zei Part number is printed internal function on module LIMITER SPECIFICATIONS Refer to parts manual or microfiche for part number and application PART NO TYPE FUNCTION LIMIT RPM COMMENTS 4060204 LR44 2 Reverse Limit 3100 ETC Limit 1400 SALES INC ELECTRICAL REVERSE LIMIT SYSTEM LR44 R Limit S COLOR CODE ENGINE GROUND BLK BLACK O BROWN WIRE GROUND BRN BROWN GRN GREEN NC SWITCH NORMALLY CLOSED UR P
24. nt of the upper panelwhere they snap into the lower panel surrounding the headlight assembly Also disengage the tabs on the upper panel which engage with the lower triangular panels on either side of the machine Lift off the upper panel and set it aside SALES INC ELECTRICAL HEADLIGHT LAMP REPLACEMENT CONT 7 Reinstall the gas tank cap 8 Remove the panel surrounding the headlight by remov ing the Phillips screws from either side of this panel Also remove the two Torx screws at the rear of this panel 9 Ease the panel forward and up to allow you to reach the socket connected to the headlight lamp 10 Carefully unplug the socket from the lamp Remove the panel and set it aside CAUTION Do not service while headlight is hot Serious burns may result 11 Stand the panel containing the headlight assembly on end to allow access to the back of the headlight assem bly 12 Disengage the wire bail holding the headlight lamp in place and move it out of the way 13 Grasp the base of the lamp and lift it out 14 Reverse the previous steps to replace the lamp and reassemble the panels NOTE Do not touch a halogen lamp with bare fingers Oil from your skin leaves a residue causing a hot spot which will shorten the life of the lamp Hold the lamp by the base SALES INC ELECTRICAL TAILLIGHT BRAKELIGHT LAMP REPLACEMENT If the taillight brakelight does not work the lamp may need to be replaced 1 F
25. r rectifier Using a multitester perform an No remove the recoil and flywheel Alternator Output AC amp test See Inspect the flywheel magnets sta test procedure on page 10 18 for proce tor coils and stator wire harness dure for damage Repair or replace Is output above 5 amps any damaged components Yes Meter Setting DC Volts Reconnect the alternator wires Note Red 3 i wire must be connected to harness Battery Check regulator rectifier connections voltage must be present on red wire terminal and ground battery connections cir on harness side of voltage regulator connector cuit breaker and connecting wires Repair or replace faulty wiring or Is it components Yes If all of the previous tests indicate a good condition but the charging voltage does not rise above battery voltage at the connector or terminal board replace the voltage regulator SALES INC ELECTRICAL CURRENT DRAW KEY OFF CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running Damage will occur to light bulbs and speed limiter 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 com ponent wiring as well as the component for partial shorts to ground to eliminate the draw Current Draw Key Off Maximum of 02 DCA 20 mA C
26. rom the rear of the taillight remove two screws hold ing lens cover in place and remove lens cover 2 Remove lamp and replace it with recommended lamp Apply dielectric grease PN 2871027 3 Reinstall the lens cover removed in step 1 4 Test the taillight brakelight to see that it s working INDICATOR LAMP REPLACEMENT 1 With a small flat screwdriver gently pry loose the indi cator light cover 2 Using a small flexible tube Such as an oil delivery hose grasp the burned out lamp and remove it 3 Replace the removed lamp with a Polaris PN 4030042 4 Replace the indicator light cover NOTE Check all lights daily for proper operation replace or repair if necessary 04 PARS SALES INC ELECTRICAL TIMING CHECK PROCEDURE 1 The ignition timing check hole is in the starter recoil magneto housing Remove the check plug NOTE The ignition timing marks are stamped on the outside of the flywheel Ignition timing must be inspected with the engine at room temperature 68 F 20 C 2 With the transmission in neutral start the engine and set engine speed to 3500 200 RPM 3 Direct the timing light at the ignition timing check hole and check the ignition timing NOTE Do not allow the engine to warm up The timing will retard approximately 2 when the engine is warm If the ignition timing is not within the specified range adjust the stator plate position as described below Flywheel Rotation 32
27. s the lower level the battery should be removed and distilled water should be added to the upper level line To remove the battery 1 Disconnect holder strap and remove cover 2 Disconnect battery negative black cable first Maintain followed by the positive red cable between upper and lower level N CAUTION marks Whenever removing or reinstalling the battery disconnect the negative black cable first and reinstall the negative cable last 3 Disconnect the vent hose 4 Remove the battery 5 Remove the filler caps and add distilled water only as needed to bring each cell to the proper level Do not overfill the battery A To refill use only distilled water Tap water contains minerals which are harmful to a battery ba Do not allow cleaning solution or tap water to enter the battery It will shorten the life of the battery 6 Reinstall the battery caps BATTERY INSTALLATION 1 Clean battery cables and terminals with a stiff wire brush Corrosion can be removed using a solution of one cup water and one tablespoon baking soda Rinse will with clean water and dry thoroughly 2 Reinstall battery attaching positive red cable first and then the negative black cable Coat terminals and bolt threads with Polaris dielectric grease PN 2871027 3 Install clear battery vent tube from vehicle to battery vent WARNING Vent tube must be free from obstructions and kinks and securely installed If not b
28. test With the tester on the VDC position place the tes ter s black lead on the battery negative and the red lead on the battery positive Remove battery and properly service Install fully charged shop battery to continue Reading should be 12 4 or greater test d GEES Check voltage on both sides of circuit Disconnect White Red engagement coil wire from breaker ignition switch engine stop switch the starter solenoid Connect tester black wire to battery ground Connect red tester lead to Whit E Red harness wire at solenoid Turn on ignition tion switch and engine stop switch must be switch and depress the starter button Tester on and the starter button depressed Re should read battery voltage place the defective component Test starter solenoid coil by connecting an ohmmeter between the solenoid red wire and the solenoid mounting plate Resistance should be 3 4Q Yes Check solenoid ground path by measuring resistance between mounting Voltage Drop Testing plate and battery negative terminal See Page 10 19 for instructions Reconnect the solenoid Connect the tester black lead to the battery positive and the red lead to the Clean the battery to solenoid cable ends or replace the cable solenoid end of the battery to solenoid wire De No press starter button Reading should be less than 1 V D C Yes Connect the black tester lead to solenoid end of battery to solenoid cable Connect red tester lead
29. the ETC switch at the harness connector NOTE Adjust throttle cable freeplay ETC switch and make sure throttle mechanism is functioning properly before testing the switch Refer to Maintenance Chapter 2 for cable adjustment procedure Turn ignition key and engine stop switch On If voltage is present on the White wire and throttle cable is adjusted properly replace the ETC switch JL w w Normal Fault ETC Operation Test Remove throttle block cover Place transmission in neutral and apply parking brake Start engine and open throttle lever slightly until engine RPM Button is above the ETC Limit see page 10 27 for LR module ETC limits Hold throttle cable with fingers at point A as shown at right and release throttle lever If the ETC system is functioning properly engine RPM will be limited to the speci fied ETC Limit RPM Refer to Speed Limiter System Testing on page 10 29 BI K Electronic Throttle Control ETC Switch Cast Aluminum Throttle Housing e CDI UNIT BEHIND OIL TANK PLU ak R IGNITION COIL BEHIND sae l OIL OPE ED TANK SWITCH RUN Lf 4 R BI R W SPARK PLUG gen OPEN amp CLOSED ETC SWITCH CLOSE ON THROTTLE RUN RUN 4 R W CABLE SLACK BLK IN THROTTLE OFF RUN l HOUS ING W SWITCH LEF
30. til the electrolyte s specific gravity reaches 1 270 or greater eStore the battery either in the machine with the cables disconnected or put it on a piece of wood and store in a cool place NOTE Stored batteries lose their charge at the rate of 1 per day They should be recharged to a full charge every 30 to 60 days during a non use period If the battery is stored during the winter months the electrolyte will freeze at a higher temperature as the battery dis charges The chart at right indicates freezing points by specific gravity CHARGING PROCEDURE Charge the battery with a charger no larger than 1 10 of the battery s amp hr rating for as many hours as needed to raise the specific gravity to 1 270 or greater of Electrolyte Point 1 Install battery in vehicle with positive terminal toward the front Coat threads of battery bolt with Polaris corrosion resistant dielectric grease Polaris Dielectric Grease PN 2871329 Nyogel To avoid the possibility of explosion connect positive red cable first and negative black cable last 2 Connect battery cables 3 After connecting the battery cables install the cover on the battery and attach the hold down strap 4 Install clear battery vent tube from vehicle to battery vent WARNING Vent tube must be free from obstructions and kinks and securely installed If not battery gases could accumulate and cause an explosion Vent should be routed away from frame and body to pre
31. to solenoid end of solenoid to starter cable De press starter button Reading should be less than 1 V D C No Replace the starter solenoid Yes Connect the black tester lead to the solenoid end of the solenoid to starter cable Connect the red tester Clean the solenoid to starter cable ends or lead to the starter end of the same cable Depress No replace the cable the starter button The reading should be less than 1 V D C Yes If all of these indicate a good condition yet the starter still fails to turn the starter must be removed for static testing and inspection ELECTRICAL STARTER MOTOR DISASSEMBLY NOTE Use electrical contact cleaner to clean starter motor parts Some solvents may leave a residue or damage inter nal parts and insulation 1 Note the alignment marks on both ends of the starter motor casing These marks must align during reassembly 2 Remove the two bolts washers and sealing O Rings Inspect O Rings and replace if damaged 3 Remove brush terminal end of housing while holding other two sections together SALES INC ELECTRICAL STARTER MOTOR DISASSEMBLY CONT 4 Remove shims from armature shaft NOTE All shims must be replaced during reassembly BRUSH INSPECTION REPLACEMENT 1 Using a digital multitester measure the resistance between the cable terminal and the insulated brush The reading should be 2 ohms or less Measure the resistance between the
32. ty Off 4010202 185 F 85 C 7 F 165 F 74 C 8 F SALES INC ELECTRICAL FAN MOTOR CURRENT DRAW DMM Fan Motor A current draw test will provide a good indication of fan S motor condition A worn or damaged fan motor will draw SES R W 4 more current which causes a reduction in blade speed go and reduced cooling Brn 1 Disconnect the Red White wire from the fan motor 2 Connect a DC ammeter in series between the Fan Switch battery and fan motor as shown at right Use the lt G l Red White wire in the wiring harness as the power supply Connect ammeter to 3 Be sure fan blade is free to rotate R W wire battery power 4 Turn ignition key and engine stop switch to ON side of wiring harness position Read the current draw on ammeter with fan running 5 Ifthe fan motor draws more than 6 5 Amps replace the motor Fan Motor Current Draw Less Than 6 5 Amps BRAKE LIGHT SWITCH Remove fuel tank Disconnect wire harness from switch Connect an ohmmeter across switch contacts Reading should be infinite Apply brake at handlebar lever and check for continuity between switch contacts Replace switch if there is no continuity or greater than 5 ohms resistance when the brake is applied with slight pressure Fon HEADLAMP SWITCH Remove the fuel tank and top cover Disconnect the headlamp switch wires Red White Green
33. ty stator measure resistance of all ignition related windings elncorrect wiring inspect color coding in connectors etc eFaulty ignition coil winding measure resistance of primary and secondary eWorn magneto RH end Crankshaft bearings eSheared flywheel key eFlywheel loose or damaged Trigger coil air gap too wide where applicable should be 016 040 4 1 0 mm eExcessive crankshaft runout on magneto RH end should not exceed 0024 eFaulty CDI module SALES INC ELECTRICAL INITIAL BATTERY SERVICE A WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with 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 physician immedi ately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame ciga rettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN WARNING The gases given off by a battery are explosive Any spark or open flame near a battery can cause an explosion which will spray battery acid on anyone close to it If battery acid gets on anyone wash the affected area with large quantities of cool water and seek immediate medical attention To ensure maxi
34. und path for the fan motor is through the Brown harness wire CAUTION Keep hands away from fan blades during this procedure Serious personal injury could result NOTE The fan switch may not function or operation may be delayed if coolant level is low or if air is trapped in the cooling system Be sure cooling system is full and purged of air Refer to Maintenance chapter 2 FAN CONTROL SWITCH BYPASS TEST Disconnect harness from fan switch on radiator Place a jumper wire between the wires in the connector Turn ignition key and engine stop switch ON The fan should start running If the fan runs with the jumper wire installed check the fan control switch and connector terminals If the fan does not run or runs slowly with the jumper wire installed check the fan motor wiring ground and motor condition refer to Fan Motor Testing this section Repair or replace as necessary FON gt FAN CONTROL SWITCH OPERATION TEST 1 Place switch in a water bath and submerse it to the base of the threads Do not allow threads to contact container or inaccurate reading will result 2 Heat the coolant slowly and monitor the temperature with a thermometer or Fluke meter pyrometer The switch should be closed conductive at the ON temperature indicated in the chart and stay conductive until the OFF temperature is reached REFER TO PARTS MANUAL FOR FAN SWITCH APPLICATION Fan Switch Part Number Continuity On No Continui
35. vent contact with electrolyte Avoid skin contact with battery electrolyte severe burns could result If electrolyte contacts the vehicle frame corrosion will occur 5 Route cables so they are tucked away in front and behind battery SALES INC ELECTRICAL CHARGING SYSTEM TESTING Whenever charging system problems are suspected proceed with the following system check Using a multitester set on D C volts mea sure the battery open circuit voltage See Remove the battery and properly ser vice Reinstall the fully charged battery page 10 13 It should be 12 4 volts or more Is it ES or a fully charged shop battery Yes Meter Setting DC Volts With the transmission in neutral start the engine and increase RPM to between 3000 and 4000 Read battery voltage with the V Check Key off Current Draw multitester Readings should be between es 13 0 and 14 6 V D C Are they Check for owner modification and discuss operating habits The battery will continually discharge if operated below the Break Even RPM Con tinued problems would call for battery inspection Meter Setting DC Amps Perform system Break Even Amperage test outlined on page 10 17 Yes Does charging occur as specified Meter Setting AC Amps Inspect the wiring harness be Disconnect the Yellow Red Yellow and Yel tween the panel and the stator for low Brn if applicable wires from the regula damage If no damage is found to
36. wer is delivered to the hot light via the Red White wire The Blue White wire ground out of the light socket is connected to the coolant temperature sensor on the cylinder head In normal operating conditions the temperature sensor is non conductive open If engine coolant reach es the specified temperature the sensor becomes conductive completing the ground path for the light With engine cold disconnect lead and measure resistance of sensor between connector terminal and ground There should be no continuity or very high resistance negohms To test the ON temperature heat the switch in a water bath to the temperature shown in table below The switch should become conductive low resistance at indicated temperature Do not immerse switch past the threads or allow switch to contact container when heat ing Hot Light On 221 F 105 C HOT LIGHT CIRCUIT TEST Disconnect temperature sensor wire lead and short it to ground on the cylinder head Turn key and auxiliary switch to ON position The hot lamp should come on Check the bulb and related wiring if the lamp does not illuminate SALES INC ELECTRICAL FAN CONTROL CIRCUIT OPERATION TESTING The fan switch is located on the radiator Power is supplied to the fan switch via the Red White wire when the ignition key and auxiliary shut off switch are ON When the fan switch reaches the specified temperature it be comes conductive and sends power to the fan motor The gro

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