1999 Polaris Service Manual
Contents
1. 4500 5000 5500 6000 6500 gs s 5 9 10 98 9 12 Polaris Industries Inc Timing Curve 1999 800 XCR ELECTRICAL Timing Curve Template 25 cem DOMUS ucc 20 e 15 oe 10 f q See ox 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 Timing is measured with throttle position sensor TPS unplugged Timing Table Polaris Industries Inc 4000 26 7500 20 8000 16 9 13 10 98 86 01 L 6 ouj seujsnpu Suejod Domestic 600 Domestic 700 Domestic 440 Domestic 500 EC59PL EC68PL EC70PL EC75PL EC40PL EC44 2PM EC44 3PM EC45PL EC50PL EC60PL EC79PL EC58PL EC65PL EC80PL DEG 112 MM ROD 120 MM ROD 125 MM ROD 103 MM ROD 120 MM ROD 128 MM ROD 136 MM ROD BTDC 60 MM STROKE 65 MM STROKE 65 MM STROKE 55 6 MM STROKE 60 MM STROKE 64 MM STROKE 68 MM STROKE EC45PM ECSSPM m O RE m N 2 0 2835 00104 02793 0 0110 02979 0 0117 0 3166 0 0125 0 015 63 4 0 305 3432 0 0135 0 3646 0 0144 0 3889 0 0153 0 4132 0 0163 MM INCHES MM INCHES MM INCHES MM INCHES MM INCHES MM INCHES MM INCHES 2 0 0232 0 0008 00252 00010 00249 0 0521 00021 0 0565 0 0022 00561 0 0022 0 0484 0 0019 0 0514 0 0020 00548 0 0022 0 0582 0 1558 0 1426 0 1617 0 1933 0 00822. 7 2 0 3 0 0303 1393 0 1579 4 2602 0 1677 tasa 40452 01993 43149 01699 4 5846 0 1805 0 1709 5807 0 1390 26 38110 61500 41379 0 1629 4 1088 otste 3537 01815 4 0 1823 472 0 1829 49558 0 1951 52655 0 2073 9 4 4528 8062 28 084 371 0 1829 5 0282 0 1980 54595 0 2149 5 4149 0 2132 4 6667 0 1837 49604 0 1953 160 i 2 04677 0 0164 05079 0 0200 05036 00198 04341 0 0171 0 4612 10 0 021 1 0 0296 0 025 2 0 0352 13 09724 0 0383 1 0559 0 0416 1 0470 0 0412 0 9025 0 0355 14 11265 0 0444 12232 00482 12129 0 0478 1 0456 0 0412 11108 00437 1 1849 0 0466 1 2589 0 0496 15 1 2617 0 0509 1 4026 00552 1 3008 00548 11989 0 0472 12737 0 0501 13586 00535 14435 0 0568 14678 0 0578 15938 0 0527 15804 0 0622 13624 0 0536 1 4474 00570 1 5439 0 0608 1 6404 0 0646 17 16546 0 0652 17969 0 0707 17818 0 0701 15359 00605 16316 0 0642 1 7406 0 0685 18494 00728 18 1 9487 2 0705 21681 0 0884 2 3036 0 0907 20 22802 00898 24759 0 0975 24552 0 0967 2 1163 0 0833 22487 0 0885 23986 0 0944 25485 0 1003 21 25098 0 0988 27252 0 1073 27024 0 1064 2 3204 0 0917 24752 0 0974 26402 0 1039 28052 0 1104 22 27497 0 1083 29857 01175 29608 01166 25521 0 005 27119
3. RPM Q Depending On 5 Engine See Data Lr 1000 2000 3000 4000 5000 6000 7000 8000 8 RPM J NOTE Always verify timing of engine at room temperature only 68 F 20 C and at the proper RPM To obtain the best ignition timing accuracy and reduce the chance of error the ignition timing specification is given at a flat portion of the advance curve This flat portion on the curve is where the ignition timing is specified Refer to chart on page 9 1 Ignition timing must be checked at the specified RPM or inaccurate timing will result Refer to timing specifications at the beginning of this chapter If engine damage has occurred due to a suspected ignition related problem verify the ignition timing is correct at the specified operating RPM as outlined on page 9 1 Dial Indicating The Timing Marks Due to differences between engines it is necessary to dial indicate the timing marks on all engines before attempt ing to adjust the ignition timing To indicate the marks 1 Remove the mag RH cylinder spark plug and install the dial indicator 2 Rotate the crankshaft by hand while observing the dial indicator As the piston touches the indicator plunger the dial will begin to rotate Find the point where the pointer stops rotating and reverses direction This will be TDC Top Dead Center 3 While holding the crankshaft with the piston at TDC zero the indicator by rotating the bezel until
4. System Troubleshooting 9 39 1999 Wiring Diagrams 9 40 9 49 ELECTRICAL Ignition Specifications 1999 Ignition Timing Specifications Operating Timing BTDC Engine MM Inches Degrees Acceptable Range RPM Model BTDC BTDC e RPM Inches EC34 2PM051 5 129 161 15 5 7000 EC44 3PM025 3 81 150 133 167 16 6500 157 195 17 e 6500 45 175 SN44 44 98A1 3 72 146 2541 5 3 29 4 16 129 163 16 8250 3500 EC50PM044 81 150 26 1 5 3 39 4 25 133 167 16 6500 3000 45 175 2 EC45PM011 4 3 133 EC55PM011 021 4 27 1 5 3 97 4 93 157 195 17 6500 3000 EC50PL162 172 3 91 4 87 156 191 16 7500 192 202 EC58PL160 3 91 4 87 156 191 20 7500 EC58PL131 28 1 5 3 91 4 87 156 191 20 7500 23000 SN50 44 99A2 034 12 1 5 664 1 08 026 042 16 8250 23000 SN60 70 99A1 A2 220 009 TUA 115 325 004 013 13 9 7500 6 1 5 115 325 004 013 17 7500 21750 SN70 70 99A1 A2 220 009 30 037 1241 5 710 1 15 033 041 16 8250 098 SN70 70 99A3 9 1 3000 20 1 5 2 10 2 81 083 111 18 8100 21750 EC79PL011 4 104 162 2641 5 3 65 4 56 144 179 15 8300 3250 EC70PLO 11 2 476 Engine at room temperature Coil Resistance Specifications For ignition system component specifications refer to wiring diagrams at the e
5. higher temperatures as the battery discharges The chart indicates freezing points by specific gravity 1150 A WARNING 1 050 Battery electrolyte is poisonous It contains acid Serious burns can result from contact with the skin Charging Procedure eyes or clothing ANTIDOTE Charge battery with a charger no larger than 1 10 of EXTERNAL Flush with water the battery s amp hr rating for as many hours as need INTERNAL Drink large quantities of water or milk ed to raise the specific gravity to 1 270 or greater Follow with milk of magnesia beaten egg or vegeta ble oil Call physician immediately A WARNING EYES Flush with water for 15 minutes and get prompt medical attention The gases given off by a battery are explosive Any Batteries produce explosive gases Keep sparks spark or open flame near a battery can cause an explo flame cigarettes etc away Ventilate when charging or using in closed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN sion 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 im mediate medical attention 10 98 9 24 Polaris Industries Inc ELECTRICAL Dynamic Testing of Electric Starter System Condition Starter fails to turn motor or motor turns slowly NOTE Be sure the engine crankshaft is free to turn before proceeding For this test a d
6. o1 saaibag WBYD UOIS13AUOD ELECTRICAL Twin Cylinder Fan CDI Ignition Exploded View Timing 1999 Indy 340 340 Dix 340 Touring Sport Sport Touring Transport Trail Trail Touring Stator Plate Lighting Coil CDI Control Unit 180 and 200 Watt Pulseless NOTE Always verify timing of engine at room temperature only 68 F 20 C Refer to ignition timing procedure on page 9 22 NOTE Acceptable variance is usually one line on either side of the dial indicated blower housing stationary line Blower Housing Stationary Lines Flywheel Mark Polaris Industries Inc 9 15 10 98 ELECTRICAL Twin Cylinder Fan CDI Ignition Exploded View Timing 1999 XCF Super Sport Trail RMK Stator CDI System 240 Watt System NOTE Always verify timing of engine at room temperature only 68 F 20 C Refer to ignition timing procedure on page 9 22 NOTE Acceptable variance is usually one line on either side of the dial indicated blower housing stationary line Blower Housing Stationary Lines Flywheel Mark 10 98 9 16 Polaris Industries Inc ELECTRICAL Fuji Twin Cylinder Liguid CDI Ignition Exploded View Timing 1999 Indy 500 500 RMK 500 Classic Classic Touring Widetrak LX Stator Plate Exciter RFI Cap al d Control Unit A 200 Watt System NOTE Always verify timing of engine at room temperature only 68 F 20 C Refer to ignition timing procedure
7. on page 9 22 Acceptable Variance Flywheel Flywheel Lines Rotation Stationary Pointers NOTE Acceptable variance is usually one line on either side of the dial indicated timing mark Polaris Industries Inc 9 17 10 98 ELECTRICAL Domestic Twin Cylinder CDI Ignition Exploded View Timing 1999 440 XCR 500 XC SP 600 XC SP 600 RMK 700 XC SP 700 SKS 700 RMK 280 Watt System NOTE Always verify timing of engine at room temperature only 68 F 20 C Refer to ignition timing procedure on page 9 22 Acceptable Variance Flywheel Flywheel Lines Rotation Stationary Pointers NOTE Acceptable variance is usually one line on either side of the dial indicated timing mark 10 98 9 18 Polaris Industries Inc ELECTRICAL Three Cylinder CDI Ignition Timing Exploded View Typical XLT Special XLT Classic XLT Touring Stator Lighting Exciter RFI Spark Plug Cap Secondary Cables The Exciter Coil can be identified by wire color Secondary Coils and smaller windings 280 Watt System NOTE Always verify timing of engine at room temperature only 68 F 20 C Refer to ignition timing procedure on page 9 22 Acceptable Variance Flywheel Flywheel Lines Rotation Stationary Pointers NOTE Acceptable variance is usually one line on either side of the dial indicated timing mark 10 98 Polaris Industries Inc 9 19 ELECTRICAL Three Cylinder CDI Igniti
8. to Com meter terminal Connect red lead to 10A meter terminal Disconnect engine harness from system Connect across the specified coil wires Start engine and let it idle Readings should be above 5 Amps at any RPM NOTE It is not necessary to increase RPM The reading can be obtained at idle Usage e Testing stator coil power output 10 98 9 4 Polaris Industries Inc ELECTRICAL Multimeter Usage A Amps DC used to check battery charge rate system draws etc Used to check the current flow to and from the battery Test Method 1 Make sure red lead is in the 10A terminal of the meter and the black lead is in the Com terminal of the meter 2 Disconnect battery ground wire s from battery terminal 3 Connect red meter lead to battery terminal 4 Connect black meter lead to harness ground wires and cable Do not operate electric starter if equipped or meter damage may occur Usage Testing key off current draw Testing key on current draw Testing charging system break even RPM Testing DC current flow direction is battery charging NOTE When using the DC Amp settings the red test lead must be moved to the 10A socket on the front of the instrument Polaris Industries Inc 95 10 98 ELECTRICAL Typical Timing Advance Curves Ignition Timing A Maximum Advance Depending on Model uj Uu 5 a O lt Operating
9. 0 1058 28927 0 1130 3 0735 0 1210 23 7843 01096 2 9587 0 1165 3 1560 01243 33532 0 1320 24 0260 0 1191 32156 01266 34300 56444 0 1435 3 5336 0 1508 38019 01497 32769 0 1554 5 341 6 2Jo 2 5 ojojojo v e eo O olojolo oil N NIN 01350 36444 34624 01371 37146 01462 3 9467 0 1554 30 2132 4 4 752911 0208 31 53559 0 2109 58152 0 2280 5 7679 0 2271 4 9708 0 195 02080 56361 02219 5 9884 02358 32 56928 02241 6 1807 02433 6 1306 02414 02080 55163 0 2211 59907 02359 6 3651 02506 33 038 02377 65559 02581 6 5028 0 2560 56039 0 2206 5 9575 0 2345 6 3546 02502 6 7518 0 2658 02732 6 8845 9326 0 23 0 2868 6 2693 0 2468 6656 0 2624 7 1009 0 2790 7 5543 0 2074 7 9698 37 75057 02955 5 1491 0 3208 8 0840 0 3183 6 9658 0 2742 7 4069 02916 7 9007 0 3111 83945 0 3305 03347 3s 82883 0 3263 8 9986 0 3543 8 9274 03515 7 6920 0 3028 8 1801 0 3221 8 7254 0 3422 9 3616 03176 85782 03377 91501 euiBue 1991109 JO ISI ALON sew Bulun UA 0 10 eorput ISPOUJ 9Ui5ue eui JINsuo9 s9y01s ui u pue sujfue pos uuayip 0 eng EIP e sn pue Sq18 WW 10 s uoul 124419 0 ueAuoo AjUO s 16 p ui peisi si uoneouioeds Buiu uous 2y ji 1V91419373 9 a41 9 uonisogd UOJSid
10. 0 3000 4000 5000 6000 7000 8000 Timing Table 1999 700 XC XC SP SKS seo e 29 5000 17 10 98 9 8 Polaris Industries Inc ELECTRICAL Timing Curves Timing Curve 1999 700 RMK 20 i Y W 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 RPM Dee _ wm w Polaris Industries Inc 9 9 10 98 ELECTRICAL Timing Curve Template Timing Curve 1999 440 XCR 25 20 a H 15 ra m N 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 ESL ONERE RN 7000 8000 8300 10 98 9 10 Polaris Industries Inc Timing Curve 1999 500 XC 500 XC SP ELECTRICAL Timing Curve Template 30 25 20 15 10 Polaris Industries Inc 1000 2000 3000 4000 5000 9 11 6000 7000 8000 9000 Timing Table 500 XC 500 XC SP RM Degrees 3900 12 4500 28 m 10 98 ELECTRICAL Timing Curve Template Timing Curve 1999 700 XCR 25 TT 2 9 se 9 e e Z e 20 e e e e e ve 15 M i 10 N t 4 5 je ok 0 2000 4000 6000 8000 10000 12000 Timing is measured with throttle position sensor TPS unplugged Timing Table
11. 00 watt and 250 watt 6 pulse All Polaris PWC Al PWC 6 pulse 6 Pulse 3 Pulse 2 Pulse Tachometers Tachometers for snowmobiles will have an identification marking on the back side For example The tachomter for a 500 XC will have 6 pulse or 6P written on it 10 98 9 30 Polaris Industries Inc ELECTRICAL Typical Exciter Pulser or Lighting Coil Replacement 1 Remove coil retaining screws and spacers 2 Using a pliers remove epoxy from solder joints A on the coil to be replaced 3 Unsolder connection from coil 4 Clean solder terminals B on the replacement coil and re solder to their proper wires NOTE Always position with numbers towards the outside 5 Reinstall retaining screws and spacers 6 Using a moisture proof sealant seal solder joints as shown NOTE All soldering must be done using rosin core solder 7 Test resistance of each coil prior to stator plate installation NOTE Lighting and pulseless coils are replaced in a similar manner IMPORTANT After the stator plate is reinstalled on the engine check placement of all coil leads to prevent pos sible contact with the flywheel Polaris Industries Inc 9 31 10 98 ELECTRICAL Electrical Testing Headlight Bulb Filament Continuity Test 1 2 3 Turn the Multitester dial to the ohms Q position Disconnect the wire harness from the headlight bulb Viewing the end of the bulb with the terminal blad
12. 3 Remove the two screws securing the two speed control assurance switches 4 Remove the switches noting their placement in the throttle block 5 Replace the assembly and check its operation 10 98 9 36 Polaris Industries Inc ELECTRICAL Electric Fuel Gauge Testing Use the multitester ohmmeter to test the resistance of the fuel sender The supply voltage to the gauge should be 13 5 VAC Fuel Gauge Q Q Pur Wh Brn Polaris Industries Inc 9 37 10 98 ELECTRICAL Handlebar Warmer Testing High Low Handwarmer Toggle Switch Below are the correct wire to PIN numbers 1 Blue High Circuit 2 Yellow Regulated Power A C HANDLEBAR HARNESS WIRE CONN 3 Blue Red Low Circuit 4 Blank 5 Blank 6 Blank 7 Brown Ground Circuit 8 Blank Testing 1 Disconnect handwarmer connector at the handwarmer 2 Measure the low range resistance between the SWITCH HANDWARMER Blue and Brown wires The resistance should HI LOW be 19 2 Q 3 Measure the high range resistance between the Brown and Blue Red The resistance should be 9 6 Q Thumbwarmer Toggle Switch Below are the correct wire to PIN numbers 1 White Gray To Thumbwarmer 2 Yellow Regulated Power A C 3 White Gray To Thumbwarmer 4 Blank 5 Blank 6 Blank 7 Brown Ground Circuit 8 Blank SWITCH THUMBWARMER 10 98 9 38 Polaris Industries Inc ELECTRICAL Ignition System Troubleshooting Conditio
13. CHAPTER 9 ELECTRICAL Ignition Timing Specifications 9 1 Routing Diagram Indicator Lights 340 Touring 9 2 Multimeter Usage 9 3 9 5 Typical Timing Advance Curves 9 6 Timing Curves 9 7 9 13 Conversion Chart Degrees to Piston Position 9 14 Timing Procedures Exploded Views 9 15 9 20 Timing Procedures All Models 9 21 Operating RPM Timing Check 9 22 Battery Service sutsu Sean Sees aada AA 9 23 9 24 Dynamic Testing of Electric Starter System 9 25 Static Electric Starter System Testing 9 26 Electric Starter Assembly 9 27 Starter Installation 9 28 Lighting System Output Test 9 29 Alternator Output Test 9 29 Alternator Output Pulse System 9 30 Typical Exciter Pulser or Lighting Coil Replacement 9 31 Electrical Testing 9 32 9 33 Coolant High Temperature Indicator Testing 9 34 Speed Control Assurance Operation 9 35 Speed Control Assurance Testing 9 36 Electric Fuel Gauge Testing 9 37 Handlebar Warmer Testing 9 38 Ignition
14. NGINE GND B 1 Y YELLO R W RED WITH WHITE TRACER t 1 i 1 kreml A E See page 9 25 1 Remove starter motor and disassemble See page 9 27 for exploded view Mark end covers and housing for proper reassembly 2 Remove pinion retaining snap ring spring and pinion gear 3 Remove brush end bushing dust cover 4 Remove housing through bolts 5 Slide brush end frame off end of starter NOTE The electrical input post must stay with the field coil housing 6 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate 7 Clean and inspect starter components NOTE Some cleaning solvents may damage the insulation in the starter Care should be exercised when selecting an appropriate solvent The brushes must slide freely in their holders If the commutator needs cleaning use only an electrical contact cleaner and or a non metallic grit sandpaper Replace brush assembly when worn to 5 16 8 cm or less Starter Housing and Field Coil Inspection 1 Using a digital multitester measure resistance between starter input terminal and insulated brushes The reading should be 3 ohms or less 2 Measure resistance between insulated brushes and field coil housing The reading should be infinite 3 Inspect insulated brush wire and field coil insulation for damage Repair or replace components as required Armature Testing 1 Using a digital multitester measure resistance between each of t
15. ce exists Continue Yes on with left column See ignition timing page 9 1 Follow the engine timing procedure for checking operating RPM timing Ifthe running and operating RPM timing are within limits no from page 9 22 Is the timing within limits other testing is necessary Yes No Remove the ignition kill circuit by disconnecting the single black wire Check the ignition switch throttle safety switches kill switch and between the CDI module and the machine harness Is the timing now harness for damage which can cause intermittent shorting correct problems Correct the problem Yes No Verify the correct CDI module by comparing the CU code on the box Replace the module with the correct part and readjust the ignition to the information listed in the ignition data charts at the beginning of timing this section Is it the right module No Yes Check the resistance of the coils under the flywheel Compare these Check the wiring connecting the coils and or replace the coils as values on wiring diagram Are they within limits necessary No Yes If the running RPM timing is within limits but the operating RPM timing is not acceptable replace the CDI module NOTE 3 cylinder engines fire three times per revolution At 7500 RPM the ignition is firing 21 500 times per minute Use of a timing light not capable of handling these RPMs may provide an incorrect operating RPM timing reading Use timing
16. e M Mag black terminal This reading must be less than 4 ohms 3 Turn the key to the on position The multitester should now read an open circuit OL 4 Move the tester lead from the G terminal to the switch housing and re check the reading It should also be an open circuit OL 5 Place one of the tester leads on the B Battery red terminal and the other tester lead on the S Starter blue terminal With the key in the on position there must be an open circuit OL reading 6 Turn the key to the start position The reading should be less than 4 ohms Readings other than the ones listed indicate a defective switch Polaris Industries Inc 9 33 ELECTRICAL Electrical Testing Ignition Switch Off On Start SS po FE Brn A R R W Ignition Switch Electric Start 10 98 ELECTRICAL Coolant High Temperature Indicator Testing Gircuit Ground the Black White wire here a with the engine running to test In Yel _ BIKW the light Engine Ground The indicator light is controlled by a temperature warning switch installed into the engine cooling system When engine coolant temperature reaches approximately 205 F the switch closes completing the circuit through the indicator light to ground The system should be tested periodically for proper operation Lamp Circuit Test 1 Remove wire from temperature sensing switch located under thermostat housing 2 With engine idlin
17. e proper direction of rotation to 058 BTDC 6 While holding the crankshaft at the ignition timing point as shown on dial indicator make a timing mark on the flywheel or fan blade using a piece of chalk or marker 7 Remove the dial indicator and reinstall spark plug 8 Start the engine Advance and hold the throttle at the operating RPM specified on the charts View the timing mark with the timing light The marks should be between the allowable variance indicated on the operating RPM timing specification 9 Ifthe operating RPM timing greatly varies from the specification but the standard ignition timing 1750 3000 or 3250 RPM is correct refer to the ignition troubleshooting section in this unit for corrective action 10 98 9 22 Polaris Industries Inc ELECTRICAL Battery Service Preparing a New Battery for Service To ensure maximum service life and performance from a battery it must have proper initial servicing To service a new battery the following steps must be taken NOTE Do not service the battery unless it will be put into regular service within 30 days 1 Remove vent plug from vent fitting 2 Fill battery with electrolyte to the upper level marks on the case 3 Set battery aside and allow it to cool and stabilize for 30 minutes 4 Add electrolyte to bring the level back to the upper level mark on the case NOTE This is the last time that electrolyte should be added If the level becomes low after thi
18. en allowing the engine to run As the throttle lever is actuated to an off idle position the top switch circuit is opened plunger in and the bottom switch circuit is closed plunger out The speed control circuit is still open allowing the engine to run In the event the carburetor or controls malfunction and allow the throttle cable to become slack the circuit will close both switch plungers out grounding the ignition system and causing the engine to stop Speed Control Assurance Adjustment Throttle lever free play must always provide a specified clearance between throttle lever A and throttle block B This clearance is controlled by the throttle cable sleeve s and the idle speed screw s Throttle Lever Freeplay Regular Throttle 010 030 25 8 mm EZ Throttle 050 060 1 27 1 5 mm If the idle speed screw s is adjusted inward and the cable sleeve s is not adjusted to take up the throttle lever to throttle block clearance the engine may misfire or kill upon initial throttle opening After any idle speed adjustments are made the throttle lever to throttle block clearance and oil pump adjustment must be checked and adjusted NOTE When adjustments are made on models which have more than one carburetor refer to Section 6 Car buretion for proper carburetor synchronization adjustments Polaris Industries Inc 9 35 10 98 ELECTRICAL Speed Control Assurance Testing 1 Set the m
19. es at the 9 12 and 3 o clock position connect the black multitester lead to the 9 o clock blade Touch the red tester lead to the 12 o clock terminal and then to the 3 o clock terminal noting the resistance value of each A reading of between 2 and 5 ohms is good An open reading indicates a bad element Hi Lo Beam Switch Testing 1 2 Set the multitester dial to the ohms 2 position If the Hi Lo switch has not been removed from the machine disconnect the switch to harness plug in connector With the Hi Lo switch in the Lo beam position check the resistance between the yellow and the green switch wires The reading shouid be less than 4 ohms Turn the Hi Lo switch to the Hi beam position and the multitester should indicate an open circuit OL reading Move one ofthe tester leads from the green to the red switch wire The multitester should now read less than 4 ohms Turn the Hi Lo Switch back to the Lo beam position and the meter should again read an open circuit OL Seat Harness Troubleshooting Remove the taillight lens Remove the two taillight bulbs and the brakelight bulb Separate the seat harness from the main harness by unplugging the connector at the right rear of the tank With the multitester dial set on ohms Q connect either meter test lead to the brown seat harness wire Touch the other tester lead to first the yellow wire and then the orange wire Observe the readings Readings othe
20. g ground wire to engine The temperature warning lamp on the console should light If not replace the lamp assembly or inspect wiring for shorts or open circuit Temp Light Temperature Sensor Test The temperature warning switch is normally open 1 Set the multitester on the ohms Q scale 2 Disconnect the lamp wire 3 Connect one test probe to the switch terminal and the other to engine ground The meter should show an open circuit OL This indicates a normally open switch If the switch were heated to approximately 205 F the contact in the switch would close and the reading would be less than 4 ohms If attempting to heat the sensor to close the contacts heat only in a water bath Never subject the sensor to an open flame to attempt to close the contacts as sensor damage will result 10 98 9 34 Polaris Industries Inc ELECTRICAL Speed Control Assurance Operation i Insulator Off Idle Switch Auxiliary Kill Switch Contacts Ignition Primary Conductor Plungers Outward Idle Switch Engine Ground Throttle Control Cutaway The speed control assurance consists of two series connected switches If one or both switch plungers are posi tioned inward the circuit is open and the engine will run At idle with the throttle lever properly adjusted the bottom switch circuit is open and the plunger is inward The top switch circuit is closed and the plunger is outward The speed control circuit is op
21. he pull in coil resistance which should be 3 4 ohms Starter Installation 1 Position starter motor so there is no less than 100 clearance between the ring gear and the starter motor pinion gear 2 Torgue through bolt mount bracket nuts to specification Torque 8mm drive end mount bolts to specification 4 Torque 6mm brush end bracket to specification Starter Pinion Gear Unregulated Voltage continued 1 Test resistance of lighting coil and compare to specifications in the model specific wiring diagram Reminder Meter resistance must be subtracted from reading NOTE 0 3 to 0 5 ohms may be less than the internal resistance of your meter leads or meter Before measuring the stator resistance short the meter leads together and read the display and record this measurement Subtract this reading from the stator resistance readings EXAMPLE Short meter leads together meter reads 0 7 ohms Measure stator resistance meter reads 1 10 ohms Subtract 0 7 ohms meter lead resistance from 1 10 ohms reading obtained when checking yellow lead to brown lead True reading is 1 10 ohms observed reading when checking stator 0 7 ohms meter lead resistance 0 4 ohms true stator resistance 10 98 9 28 Polaris Industries Inc Unregulated Voltage continued Turn the multitester dial to the Volts AC V position Disconnect the alternator to main harness connector at engine Connect one of the
22. he segments of the commutator The reading should indicate 3 ohms or less Measure resistance between commutator and armature shaft Reading should be infinity Place armature in a growler With the growler on position a hacksaw blade lengthwise 1 8 03 cm above armature coil laminates Rotate armature 360 If hacksaw blade is drawn to the armature on any pole the armature is shorted and must be replaced 10 98 9 26 Polaris Industries Inc ELECTRICAL Electric Starter Assembly Starter Assembly Brush and Spring Armature 1 Slide armature into field coil housing 2 Lightly grease drive end bushing and install drive end frame on armature 3 Mount starter vertically in a vice with brush end up 4 While holding negative brushes out against their springs slide brush plate down onto the commutator 5 While holding positive brush springs to the side slide positive brushes into their holders and correctly position the springs on top of the brushes 6 Using a non petroleum grease lubricate brush end bushing and slide it onto end of armature 7 Align threaded holes in brush plate and install dust cover and screws 8 Reinstall through bolts and properly tighten all screws 9 Lightly grease pinion shaft and install pinion spring stopper and snap ring Polaris Industries Inc 9 27 10 98 ELECTRICAL Starter Installation Starter Solenoid Bench Test The only test which can be done on the bench is t
23. igital multitester must be used Meter connections are shown on page 9 24 With tester on VDC place tester black lead on bat tery negative terminal and tester red lead on bat tery positive terminal A Page 9 26 Reading should be 12 6V or greater Is it No Yes Remove battery test and or service Install a fully charged shop battery to continue the test Continue with left column Disconnect red engagement coil wire from start sole noid Connect black tester wire to an appropriate ground and red lead to red harness wire at solenoid F page 9 26 Rotate ignition Key to the start posi tion Meter should read battery voltage Does it No Yes With black tester lead on ground check for voltage at large relay in terminal circuit breaker in and out terminals and across both sides red and red white of the ignition switch with switch on start Repair or replace any defective parts Reconnect solenoid connect tester black lead to battery positive terminal and red tester lead to sole noid end of battery to solenoid cable B Page 9 26 Turn key to start position The reading must be less than 1V DC Is it No Yes Clean battery to solenoid cable ends or replace cable Connect black tester lead to solenoid end of battery to solenoid cable and red tester lead to solenoid end of solenoid to starter cable C Page 9 26 Turn ke
24. light PN 2870630 or equivalent Polaris Industries Inc 9 39 10 98
25. n No Spark Disconnect the single black black white wire from the CDI Module to Check the ignition switch wire harness throttle safety switches the ignition kill circuit Does it have a spark and kill switch for proper adjustment or short to ground Repair Yes or replace as necessary No Disconnect the stator to CDI module wires Test the resistance values All except 3 cylinders If the parts of the ignition system under of the stator coils as per the wiring diagrams Are the resistance val the flywheel check OK the only remaining component is the ues within specs coil CDI module assembly Replace the module with another with the same CU number See ignition data All 3 cylinders Disconnect and check the secondary ignition coil resistances Refer to the resistance values listed in wiring diagrams If the coil resistance values are within specs replace the CDI module Isolate which component s resistance is not within specs Remove the flywheel and stator Recheck the resistances look for pinched or bare harness wires or replace the coil Refer to page 9 31 for coil replacement procedures Condition Incorrect Advance Retard Follow the engine timing procedure for checking running timing at Adjust the ignition timing by rotating the stator plate to correct the recommended RPM Is the timing within limits timing After adjusting the recommended RPM timing continue No with operating RPM timing if poor performan
26. nd of this chapter for the specific model you are working on Polaris Industries Inc 9 1 10 98 ELECTRICAL Routing Diagram Indicator Lights 1999 340 Touring 10 98 9 2 Polaris Industries Inc Multimeter Usage The easiest and most accurate method for testing modern electrical components is with a digital multitester Any good guality multitester will work However due to ease of opera tion and durability Polaris recommends the Fluke Model 73 PN 2870659 or Tektronix DMM155 See photo at right This instrument will provide a digital readout of the measured value of the test being performed Listed below are the dial symbols their meaning and what the dial setting can be used for Off Instrument Off V Volts AC measuring alternator output Used to measure AC voltage in an electrical system AC volt age is produced from every coil on the stator plate when a magnet is passed by it Test Method 1 Connect black lead to Com meter terminal 2 Connect red lead to VQ meter terminal 3 Turn selector dialto V setting 4 Connect test leads parallel with test component The polarity of the leads is not important Usage e Test unregulated voltage output of a stator coil Test regulated voltage to the lights and handwarm ers V z Volts DC measuring battery voltage volt drop etc Used to measure DC voltage produced by a battery or rectifier Test Method 1 Connect black lead
27. normal charge discharge cycle of a battery causes the cells to give off gases These gases hydrogen and oxygen are the components of water Because of the loss of these gases and the lowering of the electrolyte level it will be necessary to add pure clean distilled water to bring the fluid to the proper level After filling charge the battery to raise the specific gravity to the fully charged position 1 270 or greater Off Season Storage To prevent battery damage during extended periods of non use the following basic maintenance items must be performed 1 Remove battery from 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 CAUTION Do not allow any of the baking soda solution to enter the battery or the acid will be neutralized 2 Using a wire brush or knife remove any corrosion from the cables and terminals Make sure the electrolyte is at the proper level Add distilled water if necessary 4 Charge at a rate no greater than 1 10 of the battery s amp hr capacity until the electrolyte s specific gravity reaches 1 270 or greater 5 The battery may be stored either in the machine with the cables disconnected or on a piece of wood in a cool place NOTE Stored batteries lose their charge at the rate of 196 per day They should be fully recharged every 30 to 60 days during a non use period If stored during winter months the electrolyte will freeze at
28. ole With your head positioned so there is a straight line between your eye the stationary pointer and the crankshaft center line note the relative position between the marked flywheel line and the stationary pointer If the stationary pointer is aligned with the mark made in Step 2 or within the acceptable variance the timing is correct If the pointer is outside the variance the stator will have to be rotated either with crankshaft rotation to retard the timing or against rotation to advance it NOTE Rotate stator plate approximately the same distance as the marks must move NOTE In most cases the recoil starter housing re coil drive hub and flywheel must be removed to loos enthe stator bolts and change the timing On some engines the stator plate retaining screws can be ac cessed through the flywheel 8 Polaris Industries Inc Torgue stator plate screws and flywheel nut to specified torgue Apply Loctite 262 red to crankshaft flywheel taper if required Refer to the Specifications section for torque specifications and flywheel installation procedure for engine type 9 21 Acceptable Variance Flywheel Rotation Stationary lywheel Lines Pointers NOTE Acceptable variance is usually one line on either side of the dial indicated timing mark Liquid Cooled Blower Housing Flywheel Mark Fan Cooled 10 98 ELECTRICAL Operating RPM Timing Check All Models CAUTION D
29. on Exploded View 1999 700 XCR 800 XCR CDI Control Box RFI Caps The Exciter Coil can be identified by wire color and smaller windings Secondary Coils 280 Watt System NOTE Always verify timing of engine at room temperature only 68 F 20 C with TPS unplugged Refer to ignition timing procedure on page 9 22 Acceptable Variance Flywheel Flywheel Lines Rotation Stationary Pointers NOTE Acceptable variance is usually one line on either side of the dial indicated timing mark 10 98 9 20 Polaris Industries Inc Timing Procedure All Models ELECTRICAL CDI Ignition Timing NOTE Always check ignition timing with the engine at room temperature only 20 C 68 F Refer to the timing specification charts at the beginning of this section to determine the proper ignition timing 1 2 for the engine you are working on Use a dial indicator to place the piston in the proper timing position and mark the flywheel at this point follow procedure on page 9 7 Connect an accurate tachometer and a good guality timing light to the engine according to manufacturer s instructions Disconnect the TPS Throttle Position Sensor connector from carburetor on 700 XCR and 800 XCR Start engine and increase RPM to the point specified in the timing specification chart on page 9 1 1750 3000 3250 Hold the throttle to maintain specified timing RPM Point the timing light at the timing inspection h
30. r than an open circuit indicate a shorted harness or bulb socket NOTE The bulb socket tangs sometimes short to ground with the bulb removed Check between the yellow and orange wires in the same manner to check for a short between the brake and running lights If damaged wiring is found remove the seat Tip the seat over and remove the right side seat cover staples Locate and repair the harness problem Reinstall the staples and re check the seat harness 10 98 9 32 High Low Switch Polaris Industries Inc Ignition Switch Testing Non Electric Start 1 Set the multitester dial to the ohms 2 position Connect one of the tester leads to either of the switch terminals and the other tester lead to the other switch terminal 2 With the switch off the reading should be less than 4 ohms With the switch on the reading must be an open circuit OL 3 Check the resistance between each of the switch terminals and the switch body With the switch still in the on position there must be an open circuit OL reading Readings other than those listed indicate a defective switch Ignition Switch Testing Electric Start Models NOTE Refer to the appropriate model and year wiring diagram for ignition switch wire colors and connections 1 Disconnect wires Set the multitester dial to the onms Q position 2 With the key in the off position check the resistance between the G Ground brown terminal and th
31. s point add only distilled water 5 Charge battery at 1 10 of its amp hour rating Example 1 10 of 9 amp battery 9 amps 1 10 of 14 amp battery 1 4 amps 1 10 of 18 amp battery 1 8 amps recommended charging rates 6 Check specific gravity of each cell with a hydrometer to ensure each has a reading of 1 270 or higher Battery Testing There are three easy tests which can determine battery condition Whenever the complaint is related to either the starting or charging systems the battery should be checked first Lead acid batteries should be kept at or as near full charge as possible If the battery is stored or used in a partially charged condition hard crystal sulfation will form on the plates reducing their efficiency and possibly ruining the battery Open Circuit Voltage Test OCV Battery voltage should be checked with a digital multitester Readings of 12 6 or less require further battery testing and charging Specific Gravity Test A tool such as the battery hydrometer PN 2870836 can be used to measure electrolyte strength or specific grav ity 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
32. tem loads poor flywheel magnets lighting coil problems or wires harness problems Check for partially grounded shorted yellow wire Reconnect the yellow regulator wire and increase the RPM f the headlight was bright with the regulator disconnected and dim when connected at the same RPM the regulator or regulator ground is at fault Polaris Industries Inc 9 29 ELECTRICAL Lighting System Output 10 98 ELECTRICAL Alternator Output Pulse System 2 pulse 3 pulse 6 pulse Alternators The difference between a 2 pulse 3 pulse and 6 puise alternator system is the number of AC sine waves created by the alternator in one revolution of the crankshaft For example on a 6 pulse system the alternator will create 6 pulses or 6 complete AC sine waves in one crankshaft revolution The tachometer reads these sine waves therefore giving you accurate RPM readings A 3 pulse tachometer cannot be used on a 6 pulse system If this is done the tachometer will read double RPM Refer to the following text for applications All Polaris Snowmobiles All Fuji single cylinder and twin cylinder engines 2 pulse All Polaris Domestic twin cylinder engines 1999 440 8 550 fan cooled 6 pulse Early model three cylinder engines 500 600 650 750 early 800 3 pulse Late model three cylinder engines 580 600 680 700 800 6 pulse All Polaris ATVs All 150 watt alternators and earlier 2 pulse All 2
33. tester leads to the yellow alternator wire and the other lead to the brown alternator wire NOTE On floating alternators the yellow red stator wire should connect to the brown stator wire If it does not the system will not have a ground and will not operate Start the engine While observing the voltage reading increase the engine speed to about 3000 RPM Readings of between 15 and 45 VAC are considered normal Short Circuit Current AC Amp Test PON gt Turn multitester dial to A Connect red lead to 10A terminal Connect black lead to Com meter terminal Disconnect lighting charge coil wires from system Connect meter leads to coil wires leading to stator coils Start and idle engine Readings should be above 5 amps Referto Amps AC on page 9 4 Regulated Voltage Connect the alternator to main harness connector Insert one of the tester leads along the side of the yellow regulator wire connector between the insulation and the terminal Ground the other tester lead Start engine and observe headlight output Increase engine RPM If the headlights seem dim above 3500 RPM let the engine return to idle and disconnect the yellow wire from the regulator Carefully observe the voltage reading Do not allow voltage to increase above 14 0 volts Slowly increase RPM Voltage above 12 volts at 2500 3000 and a bright headlight indicates a good lighting coil Voltage below 10 volts at 3000 indicates excessive sys
34. the 0 on the dial and the pointer align 4 Rotate the crankshaft opposite the direction of rotation about 250 BTDC 2 1 2 pointer revolutions 5 Determine the correct ignition timing position from the ignition data charts and rotate the crankshaft in the normal direction of rotation to that position Example f engine timing is 150 BTDC the crankshaft must be rotated in the normal direction of rotation so that the dial indicator pointer does one complete revolution and stops on 50 This should be 1 1 2 pointer revolutions before top center or 150 BTDC 6 While holding the crankshaft at the correct timing position mark the flywheel with chalk or a white marker directly in line with the stationary pointer or line on the fan or recoil housing through the timing inspection window 10 98 9 6 Polaris Industries Inc ELECTRICAL Timing Curves Timing Curve 1999 600 XC 600 XC SP 600 RMK JJ a 1 9 18 eet e l s 16 a 7 14 K m d LI 12 ae ME e 10 B 8 2 6 x 4 4 2 Pa 0 er a NE 0 1000 2000 3000 4000 5000 6000 7000 8000 Timing Table 1999 600 Twin Polaris Industries Inc 97 10 98 ELECTRICAL Timing Curves Timing Curve 1999 700 XC 700 XC SP 700 SKS 20 18 ee Fa EA 0 1000 200
35. the lowest and highest cell readings indicate a need to replace the battery Lead acid Type 0 Charged Less Than Less Than 11 80V 11 9V State Of Charge Conventional Yumacron Lead acid Type 0 Charged Less Than Less Than 1 100 1 115 at 80 F Detail A NOTE Subtract 01 from the specific gravity for electrolyte at 40 F and compare these values to the chart Polaris Industries Inc 9 23 10 98 ELECTRICAL Battery Service Load Test NOTE This test can only be performed on machines eguipped with electric start This test cannot be performed if the engine or starting system is not working properly A battery may indicate a fully charge condition on the OCV test and the specific gravity test but still 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 the test hook a multitester to the battery in the same manner as 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 Refilling a Low Battery The
36. to Com meter terminal 2 Connect red lead to VQ meter terminal 3 Turn selector dial to V setting 4 Connect test leads parallel with test component Observe polarity Usage Test battery voltage e Test DC regulator Test voltage drop for bad connections e Test supply voltage to electric fuel gauge EFI electrical testing Polaris Industries Inc 9 3 RED LEAD HERE FOR AMPS COMMON BLACK LEAD ELECTRICAL Multimeter Usage 10 98 ELECTRICAL Multimeter Usage Q Ohms resistance measuring component resistance values testing coils wiring etc Used to test resistance to the flow of electricity in a circuit or component A reading of OL means an open circuit or infinite resistance Sometimes the leads themselves will have some resistance Touch the leads together and subtract this resis tance from the component reading to achieve the actual reading Test Method 1 2 3 4 5 Connect black lead to Com meter terminal Connect red lead to VQ meter terminal Turn selector dial to Q setting Isolate test component from the rest of the electrical circuit by disconnecting wires from harness Connect test leads to the circuit to be tested Usage e Testing coil resistance Testing switch operation Testing wire continuity A Amps AC used to test lighting coil output Used to test the power of an alternator coil Test Method OY Or P G J Connect black lead
37. ue to the high RPM necessary and the possible danger involved special care must be observed whenever per forming an operating RPM timing check to avoid serious personal injury This check need not be performed unless symptoms leading to poor performance and possible engine damage are present e Never operate the engine with the clutch guard open or removed e Do not stand over or around the clutch while performing this test e Perform the test as quickly as possible Avoid prolonged periods of engine free rev Operating RPM Timing Test Procedure 1 Using the charts at the beginning of this unit determine the ignition advance BTDC at the operating RPM 2 Remove the mag side spark plug and install a dial indicator in that cylinder 3 Zero the dial indicator as explained on page 9 6 4 Turn the crankshaft in the opposite direction of rotation to a point approximately 100 2 5 mm before the operating ignition timing point 5 Turn the crankshaft in the proper direction of rotation until the dial indicator shows the proper piston position BTDC for operating RPM ignition timing NOTE The charts only indicate degrees BTDC This figure must be converted using the tables on page 9 14 Example The operating timing and RPM for an engine is 16 at 7500 RPM Using the chart 16 on this engine is 058 BTDC at 7500 RPM Using a properly installed and zeroed dial indicator back the engine up to approximately 150 BTDC Then rotate the crank in th
38. ultitester in the ohms 2 position 2 Disconnect the switch harness from the main wire harness 3 Connect the two multitester leads to the two switch wires Test 1 Open Circuit Run With the auxiliary shut off switch in the ON position the multitester should read an open circuit OL As the throttle lever is moved from idle to off idle the tester should continue to read an open circuit If the tester fluctuates and the throttle lever to throttle block clearance is adjusted properly the switch assembly must be replaced Test 2 Closed Circuit Kill The two speed control switches must make a complete cir cuit to kill the engine To check the switches pull the throttle lever out away from the throttle block With the switch plung ers outward and the auxiliary shut off switch in the ON posi tion the multitester must read less than 4 ohms resistance Inspect wires and repair if damaged or replace switch as sembly Test 3 Auxiliary Shut Off The multitester should read less than 4 ohms in the OFF position and an open circuit in the the ON position Inspect wires and repair if damaged or replace switch assembly Speed Control Assurance Replacement Auxiliary shut off and speed control assurance switches are connected and replaced as a unit from the back side of the throttle block 1 Remove the handlebar pad and or throttle block backing plate 2 Slide out the auxiliary shut off portion of the switch
39. y to start position The reading must be less than AV DC Is it No Yes Replace starter solenoid Connect black tester lead to solenoid end of solenoid to starter cable and red tester lead to starter end of same cable D Page 9 26 Turn key to start posi tion The reading must be less than 1V DC Is it No Yes Clean solenoid to starter cable ends or replace cable Connect black tester lead to starter frame Connect red tester lead to battery negative terminal E Page 9 26 Turn key to start position The reading should be less than 1V DC Is it No Yes Clean ends of engine to battery negative cable or replace cable If all these tests indicate a good condition yet the starter still fails to turn or turns slowly the starter must be remove for static testing and inspection Polaris Industries Inc 9 25 10 98 ELECTRICAL Electric Starter System Testing Static Starter Motor Static Testing IGNITION SWITCH IGNITION SWITCH SYSTEM BRN GROUND ALTERNATOR m lus IGNITION WIRE COLORS OUTPUT G TERMINAL BROWN GROUND i TERMINAL RED BATTERY M TERMINAL BLACK IGNITION STIGN i S TERMINAL RED WHITE STARTER BLK NN a Disconnect R W Wire OFF RUN START RECTIFIER R C BK CIRCUIT BREAKER D TO J 1 O IGNITION SWITCH 2 STARTER RELAY M RT RS CHASSIS GNO a CODE 1 1 1 i E
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