Electronic Fuel Injection - the Polaris International Extranet
Contents
1. zung J 3 WW E STE Dt ee ate o EIERE Old OVA Holl DR Cy 2 F009 or OLOZPNI MOLEN F LILE CN FOE SC 7 BE Tana Kalb am m pd F ay Oe ITOE ot XOG IWWLNI YIY 40 201 ENWAU l GE a OR Cy ZC ei 1H914 NO 031907 i ZE000 SE d d mom x Eo i 7 L Ke2. Component Condition SPN FMI P Code Driver Circuit Open Grounded 5 P0264 Fuel Injector 2 PTO Driver Circuit Short to B 652 3 P0265 Driver Circuit Grounded 4 P1265 Rear Differential Output Driver Circuit Short to B 746 3 P1692 Driver Circuit Open Grounded 5 P1481 Fan Relay Driver Circuit Driver Circuit Short to B 1071 3 P1482 Driver Circuit Grounded 4 P1483 Driver Circuit Open Grounded 5 P1615 Starter Enable Circuit Driver Circuit Short to B 1321 3 P1617 Driver Circuit Grounded 4 P1616 Driver Circuit Open Grounded 5 P0230 Fuel Pump Driver Circuit Driver Circuit Short to B 1347 3 P0232 Driver Circuit Grounded 4 P0231 Voltage Too High 3 P1555 Throttle Release Signal Hee ae 520194 S e Signal Out of Range 2 P1553 Throttle Stuck 7 P1552 Driver Circuit Open Grounded 5 P1685 Active Descent Control ADC Driver Circuit Short to B 520203 3 P1686 Driver Circuit Grounded 4 P1687 Driver Circuit Open Grounded 5 P1681 Reverse Alarm Driver Circuit Short to B 520206 3 P1682 Driver Circuit Grounded 4 P1683 Driver Circuit Open Grounded 5 P1836 All Wheel Drive Control AWD Driver Circuit Short to B 520207 3 P1835 Driver Circuit Grounded 4 P1834 Driver Circuit Open Grounded 5 P1611 Chassis Relay Driver Circuit Short to B 520208 3 P1614 Driver Circuit Grounded 4 P1613 idle Speed Speed Too High Su 3 P0507 Speed Too Low 4
3. Fuel Tank Pressure Regulator Fuel Filters Fuel Pump Assembly Quick Connect Fuel Line 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION FUEL LINE Quick Connect Removal Installation Verify fuel system has been depressurized AA CAUTION before performing this procedure All EFI models use quick connect fuel lines Refer to the following steps for fuel line removal installation 1 2 Remove the seat and upper right side panel Thoroughly clean the connector and place a shop towel around the fuel line to catch any dripping fuel Squeeze the connector tabs together and pull out on the white retainer Push tabs in and pull out white retainer before removing Lift up on the fuel line and remove it from the pump outlet To install the line verify the connector and fuel pump outlet are clean and free of debris Place the connector end over the fuel pump outlet and push the white retainer and tabs back into place NOTE Confirm attachment by pulling on the fuel line Repeat this process when removing the fuel line from the fuel rail Fuel Pump Outlet Fuel Rail EFI SERVICE NOTES For more convenient and accurate testing of EFI components it is recommended dealers utilize the Digital Wrench Diagnostic Software dealer only or limited testing may be
4. og GE located on the Digital Wrench screen Click the SE Continue button and follow instructions provided on the nenastane jel Mey oat ee ee k screen to complete the reprogramming procedure POLARIS Ee P prog gp Engine Controller Reprogrami gt POLARIS Fe ES EE E EE Ss ae te EES Note the Request Code below and obtain an Authorization Key from the Dealer Web Request Code al Enter the Site Enter the Authorization Key in the Proper Field to Continue cay Request Code DO NOT SHUTDOWN THE SOFTWARE UNTIL REPROGRAMMING IS Stat Crew COMPLETE OR THE AUTHORIZATION KEY WILL BE LOST 62006 Diagnostic Systems Associates Request Code BBITIHGHJJOKK Authorization Key PCFACKAPAEEG E 2 Enter Authorization Key 4 Prepare Vehicl i Enter the Authorization Key 11 Select the same file type from the list that you selected previously while in Digital Wrench Enter the VIN along ga BLU Repropremaing with the customer s name and address When completed click the Authorize button once to proceed 14 At this point the reflash process will begin Do not touch EE ES ee e the vehicle or PC during the process B D mb Sey rar Engine Controller Reprogramm gt POLARIS Reprogramming in Progress Please Enter ALL of the information below Request Code fine DO NOT DISTURB THE VEHICLE OR COMPUTER UNTIL THIS PROCESS IS COMPLETE 200
5. Fuel Injector Replacement NOTE Engine must be cool Depressurize the fuel system if possible 1 Remove the seat and both upper side panels see Chapter 9 Seat and Side Panels 2 Remove the 2 screws retaining the lower portion of the air box 3 Remove the hose from the breaker valve located on top of the valve cover 4 Remove the spark plug wires 5 Remove the 2 Torx head screws retaining the upper portion of the air box to the front cab 3 17 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION 10 11 12 13 14 15 16 3 18 Carefully disconnect the ECU by pulling the tab out while pulling down on the connector Loosen the hose clamp retaining the intake boot to the intake plenum and remove the boot Lift up on the air box and turn it sideways to gain access to the fuel rail and fuel injectors Thoroughly clean the area around the fuel rail and injectors Disconnect the quick connect fuel line from the fuel rail Disconnect the harness from both fuel injectors Using a 10 mm wrench remove the fuel rail mounting screws Carefully pull up on the fuel rail and fuel injectors and remove them from the vehicle as an assembly Ft A Pry the two injector retaining tabs open and remove the injector s from the fuel rail Lubricate the O rings lightly with soapy water to aid installation of the n
6. The TPS is a non serviceable item If it is faulty it must be replaced It can be tested using the following method With the test leads connected and the meter set to the ohms scale observe the reading at the following pin locations of the TPS TPS Connector TPS Resistance Readings Pins Throttle Position Resistance GND www oO Closed 4kQ 5kQ reference 1150Q 12502 e Open reference O O Reese 4kQ 6kQ TPS Tester Regulator The TPS reading can be checked by using the Throttle Position Sensor TPS Tester 2201519 A IMPORTANT TPS Tester 2201519 A replaces the existing TPS tester 2201519 which included the 4010264 regulator If your dealership has 2201519 and 4010264 you DO NOT need to order 2201519 A as a replacement Set up the TPS Tester Wire Harness PU 47466 and TPS Tester Regulator 547927 according to the instructions that accompanied the tester Make sure the 9 Volt battery is new 2201519 A 547927 marked 4010264A Use a NEW DV Battery PU 47466 3 22 Verify TPS Tester Reference Voltage A 5 volt reference voltage from the TPS Tester harness is required for the TPS test to be accurate Refer to the instructions provided with the TPS Tester 2201519 A or follow the bullet point steps below to check reference voltage Reference Voltage Test e Insert black voltmeter probe into the test port as shown e Insert red voltmeter probe into the test por
7. see Digital Wrench Updates IMPORTANT Always operate with the latest update Digital Wrench Serial Number Location Open the configuration screen by clicking on the wrench icon The serial number is located on the right side of the screen Loea Web Help Balloons Start Up Help Auto Updates SmartLink Module Program Configuration 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION Digital Wrench Updates Updates are released for Digital Wrench via the Internet at http polaris diagsys com The Digital Wrench website can also be accessed through the dealer website at www polarisdealers com NOTE Only authorized Polaris dealers and distributors can access the dealer website 1 Log on to www polarisdealers com 2 Locate the Service and Warranty drop down menu Click on Be Wrench Updates S LS SE EY VCE aoe S mp e Term ep mi r tan A Crees e Ocomurencntcs LI k Ean POLARIS COMPUTERCHECK 015 k A Di re Special Alerts News forms A Links 4 The Digital Wrench portal website should appear in a new web browser 5 Click on Digital Wrench Version 3 1 Updates 6 If the update file date listed is newer than your current version and update see Digital Wrench Version and Update ID download the file am
8. information and view ECU JY Open the ASSERT ASK Form KH Identification Enter Edit Change Vehicle Information B Enter Edit Change Vehicle Information Open the ASSERT E Quick Start ASK Form Current Work Order New Work Order Select Existing Order Vehicle Home Page Perform specialized testing and adjustment functions A service reports Het Vehicle Selection Sr Customer Information gt peas T Wl Product Utilities System Configuration lt Digital Wrer ch Smartlink Setup Software Registration E Dd Digital Wrench Help gt System Help Digital Wrench Home Page Digital Wrench Knowledge Base il Exit Open the Software Configuration Screen Set up data capture and record ag functions Run The Help System E View information from the fimum main ECU Sensors Prints the current screen as z a formatted printout S This is the most viewed screen View ET sensor and ECU information in a grid meter or chart format ES Exit The Diagnostic System View or clear trouble codes in the d Engine Controller memory z Load the Vehicle Home Page l 3 35 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION Engine Controller Reprogramming Reflash Process Overview The reprogramming feature is in the Special Tests menu on the Digital Wr
9. on page 3 33 3 Open the Digital Wrench program 4 Select the model year product line and vehicle description by selecting the Change Vehicle Type icon gt POLARIS See Wrench r Digital Wreech ASK Form te ret te teeter pepe Jeet tre Nee Version 3 1 04 27 09 2009 Sportsman XP 550 EPS Status 5 Select the Special Tests icon zz Digital Wrench r gt POLARIS Digal Wrrech ASK Form a ee ee tee tee Version 3 1 04 27 09 2009 Sportsman XP 550 EPS Status 6 Select Engine Controller Reprogramming 2009 Sportsman XP 550 EPS Status 7 Select the file you want to load into the ECU then click the Continue icon to proceed to the Integrity Check and obtain a Request Code k Engine Controller Reprogramm gt POLARIS Select the Proper ECU Program from ti the List Below The Same ECU Program Must Be Selected When Requesting an Authorization Key from the Dealer Website DO NOT CONTINUE UNLESS THE VEHICLE BATTERY IS FULLY CHARGED USE A BATTERY CHARGER IF NECESSARY Reflash Database Version 2 16 1 Select File 2009 Sportsman XP 550 EPS Status 8 Copy CTRL C the Request Code that will be required on the dealer website in the next step DO NOT CLOSE Digital Wrench or the Request Code will be invalid NOTE All characters are letters there are no nu
10. ECU It is sealed to prevent damage to internal components Warranty is void if the case is opened or tampered with in any way All operating and control functions within the ECU are pre set No internal servicing or readjustment may be performed If a problem is encountered and you determine the ECU to be faulty contact the Polaris Service Department for specific handling instructions Do not replace the ECU without factory authorization The relationship between the ECU and the throttle position sensor TPS is very critical to proper system operation If the TPS is faulty or the mounting position of the TPS to the throttle body is altered the TPS must be adjusted For the purpose of troubleshooting a known good ECU from another Polaris Sportsman 850 of the same model may be used without system or engine component damage 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION ECU Removal Replacement 1 Remove the seat and upper left hand side panel see Chapter 9 Seat and Side Panels 2 With the ignition turned off disconnect the wire harness from the ECU by pulling the black slider out away from the ECU while pulling down on the connector Once the slider is fully extended pull the connector from the ECU using care not to damage the connector or locking mechanism 3 Remove the 4 screws retaining the ECU to the airbox and remove the ECU 4
11. P0506 Steering Over Current Shut Down Current Above Normal or Grounded 520221 6 C1050 Steering Excessive Current Error Current Above Normal or Grounded 520222 6 C1051 Steering Torque Partial Failure Condition Exists 520223 31 C1052 3 30 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION DIAGNOSTIC TROUBLE CODE TABLE G Digital Wrench Component Condition SPN FMI P Code Steering Torque Full Failure Condition Exists 520224 31 C1053 Greater than 110 C 230 F 16 C1054 EPS Inverter Temperature 520225 Greater than 120 C 248 F 0 C1055 ERS CAN Communisations No RX Message for 2 Seconds 520226 2 U0100 Receive Error EFS GAN NEES No TX Message for 2 Seconds 520227 2 U1100 Transmit Error Position Encoder Error 520228 11 C1065 EPS Software Error Software Error 520229 12 C1070 IC CAN Communication with EPS EPS Off Line EPS DM1 not seen 520230 31 U0131 3 31 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION DIGITAL WRENCH OPERATION Digital Wrench Diagnostic Software Overview IMPORTANT Refer to Section 2 3 and 4 in the Instruction Manual provided in the Digital Wrench Diagnostic Kit to install the Polaris Digital Wrench diagnostic software on your computer The Digital Wrench diagnostic software a
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13. Voltage Too Low 4 P0122 Data Erratic Intermittent or Missing 2 P0503 Vehicle Speed Signal 84 Received Vehicle Speed Has Error 19 C1069 Voltage Too High 3 P0108 Manifold Absolute Pressure Sensor T MAP Voltage Too Low 102 4 P0107 Signal Out of Range 2 P0106 Intake Air Temperature T MAP Voltage Too High H 3 P0113 Voltage Too Low 4 P0112 Voltage Too High 3 P0118 Voltage Too Low 4 P0117 Engine Temperature Sensor ECT 110 Temperature Too High 16 P0217 Engine Overheat Shutdown 0 P1217 P0563 Voltage Too High 168 3 C1063 System Power P0562 Voltage Too Low 168 4 C1064 Engine Speed Too High 0 C1059 Engine Speed 190 Received Engine Speed Has Error 19 C1066 Voltage Too High 3 P0917 Gear Sensor Signal Voltage Too Low 523 4 P0916 Signal Fault 2 P0914 ECU Memory EEProm Read Write Failure 628 12 C1073 Calibration Checksum CRC Error 630 13 C1074 Driver Circuit Open Grounded 5 P0505 Driver Circuit Short to B 3 P0509 Idle Air Control IAC 634 Driver Circuit Grounded 4 P0508 Position Out of Range 7 P0519 Circuit Fault 8 P0336 Crankshaft Position Sensor CPS 636 Plausibility Fault 2 P0335 Driver Circuit Open Grounded 5 P0261 Fuel Injector 1 MAG Driver Circuit Short to B 651 3 P0262 Driver Circuit Grounded 4 P1262 3 29 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION DIAGNOSTIC TROUBLE CODE TABLE Digital Wrench
14. and spark requirements for the immediate operating conditions The ECU then sends output signals to set the injector duration and ignition timing During operation the ECU continually performs a diagnostic check of itself each of the sensors and system performance If a fault is detected the ECU turns on the Check Engine light in the speedometer and stores the fault code in its fault memory Depending on the significance or severity of the fault normal operation may continue or Fail Safe operation slowed speed richer running may be initiated A technician can determine the cause of the Check Engine light by referencing the Instrument Cluster Trouble Code Display and Diagnostic Trouble Code Table or by using Digital Wrench The ECU requires a minimum of 7 0 volts to operate The memory in the ECU is operational the moment the battery cables are connected 3 10 To prevent engine over speed and possible failure an RPM limiting feature is programmed into the ECU If the maximum RPM limit 8000 is exceeded the ECU suppresses the injection signals cutting off the fuel flow This process repeats it self in rapid succession limiting operation to the preset maximum Maximum RPM Limit 8000 SPORTSMAN 850 RPM Limit Hard Limit Fuel injector suppression occurs e All Gears 8000 RPM Soft Limit Spark timing suppression occurs e All Gears 7500 RPM ECU Service Never attempt to disassemble the
15. 0 Polaris Sales Inc ELECTRONIC FUEL INJECTION Ignition Coil and HT Lead Replacement NOTE The plug caps or coil ends are not removable The high tension lead coil wire must be replaced as an assembly 1 7 Remove the seat and upper right hand side panel to access the ignition coil see Chapter 9 Seat and Side Panels Disconnect the shift linkage and remove the high tension lead caps from the spark plugs Remove the high tension leads from the airbox Disconnect the harness from the ignition coil Using a T20 driver remove the screw retaining the ignition coil to the airbox Remove the coil assembly and disconnect the high tension leads by pulling on the coil side end caps Install the new high tension leads NOTE Be sure to install the PTO long wire on the coil terminal nearest the airbox 8 10 Install the coil assembly and securely tighten the mounting screw Upon assembly make sure the high tension leads are retained by the airbox Reinstall the shift linkage upper right hand side panel and the seat 3 27 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION EFI DIAGNOSTICS Instrument Cluster Trouble Code Display NOTE The diagnostic mode is accessible only when the check engine MIL has been activated Use the following procedure to display diagnostic trouble codes that were activated during current i
16. 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION ELECTRONIC FUEL INJECTION General Information The Electronic Fuel Injection EFI system is a complete engine fuel and ignition management design This system includes the following principal components Fuel Pump Fuel Filters Pressure Regulator Fuel Line Fuel Rail Fuel Injectors Throttle Body Integrated Air Fuel Manifold IAFM Electronic Control Unit ECU Ignition Coil Engine Coolant Temperature Sensor ECT Throttle Position Sensor TPS Crankshaft Position Sensor CPS Intake Air Temperature Manifold Absolute Pressure Sensor T MAP Idle Air Control AC Wire Harness Assembly EFI Operation Overview The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions The ignition and injection functions are electronically controlled monitored and continually corrected during operation to maintain peak performance The central component of the system is the Bosch Electronic Control Unit ECU which manages system operation determining the best combination of fuel mixture and ignition timing for the current operating conditions An in tank electric fuel pump is used to move fuel from the tank through the fuel line to the fuel rail The in tank fuel pressure regulator maintains a system operating pressure of 43 psi and returns any excess fuel to the
17. 6 Diagnostic system Associates Enter ALL the information and click on the Authorize button k 2009 Sportsman XP 550 EPS Status 15 Once the ECU reprogramming procedure is complete click the Finish button on the screen Verify the reflash was a success by starting the vehicle 3 38 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION FUEL SYSTEM TROUBLESHOOTING Poor idle Symptom Idle Too High If greater than 1400 RPM when engine is warm The correct position of the throttle body stop screw is established and set at the factory DO NOT remove the tamper proof cap to adjust the throttle body stop screw or Throttle stop screw tampering Throttle cable sticking improperly adjusted routed incorrectly alter its position in any manner The stop screw conirols the air flow calibration of the throttle body Failed sensor or disconnected wiring IAC stuck or inoperative e Intake air leak Fuel Starvation Lean Mixture Symptom Idle Too Low if less than 1100 RPM when engine is warm Symptoms Hard start or no start bog backfire popping through intake exhaust hesitation detonation low power e Plugged air filter spark plug erosion engine runs hot surging high idle idle e Leaking injector rich condition speed erratic e Belt dragging a DO east ae e Throttle stop screw tampering e R
18. BJ BSS GS GF CoN ir II p we sso mg 2 Press and hold the MODE button to enter the diagnostics code menu 3 A set of three numbers will appear in the information area e The first number located far left can range from 0 to 9 This number represents the total number of trouble code present example 2 means there are 3 codes present e The second number located top right can be 2 to 6 digits in length This number equates to the suspected area of fault or the Suspect Parameter Number SPN e The third number located bottom right can be 1 to 2 digits in length This number equates to the fault mode FMI PESO OOOGUGF cl CO di IE Error Code Number 0 9 Suspect Parameter Number FMI Failure Mode Identifier 4 If more than one code exists press the MODE button to advance to the next trouble code 5 To exit the diagnostic mode press and hold the MODE button or turn the ignition key OFF once the codes are recorded 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION DIAGNOSTIC TROUBLE CODE TABLE G Digital Wrench Component Condition SPN FMI P Code Voltage Too High 3 P0123 Throttle Position Sensor TPS 51
19. EFI relay provides voltage to the injectors During engine operation the ECU completes the ground circuit energizing the injectors The valve needle in the injector is opened electromagnetically and the pressure in the fuel rail forces fuel down through the inside The director plate at the tip of the injector contains a series of calibrated openings which directs the fuel into the intake port in a cone shaped spray pattern The amount of fuel injected is controlled by the ECU and determined by the length of time the valve needle is held open also referred to as the injection duration or pulse width It may vary in length depending on the speed and load requirements of the engine Fuel Injector Service Injector problems typically fall into three general categories electrical dirty clogged or leakage An electrical problem usually causes one or both of the injectors to stop functioning Several methods may be used to check if the injectors are operating NOTE Do not apply voltage directly to the fuel injectors Excessive voltage will burn out the injectors Do not ground the injectors with the ignition on The injectors will open if the EFI relay is energized If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem Check as follows Injector leakage is very unlikely but in rare instances it can be internal past the tip of the valve needle or exter
20. ELECTRONIC FUEL INJECTION CHAPTER 3 ELECTRONIC FUEL INJECTION SPECIAL TOS EE 3 2 PUL TANK cia Ae Go seat eebe eta ae Set le etre Relea Sh e 3 4 gy El LEE 3 5 EFI SERVICE NOTES 2 0 cts chet a Mii Ree Sela a E gee e EE 3 5 EFISYSTEM LAYOUT EE 3 6 EFI COMPONENT Sice Seier degt EE tet eko TER dEr os P E date Sane pated 3 7 ELECTRONIC FUEL INJECTION ciety Solos Sh ate oh Od e e es 3 9 ELECTRONIC CONTROL UNIT ECU 22 cs tec ci wate ane bided N 3 10 POU SERVICE os 2 oct ao ge eebe 3 10 ECU REMOVAL REPLACEMENT EN SEENEN teeing odie teed 3 11 PUBL PUMP ASSEMBLY Ee BBN tie de cpl eege e 3 11 FUEL SENDER FUEL PUMP TEStyccait ested vlacaniiatet ieonnacs wlencee manana sy 3 12 FUEL TANK REMOVAL fics Grose bach aetna haunt dt Emcee Se ae Geet 3 13 FUEL PUMP REPLACEMENT EE 3 14 FUEL TANK INTERESSE 3 16 FUEL PRESSURE REGULATOR est E Eens bereet re teen aa ee 3 16 UU e 3 17 FUEL INJECTOR SERVICE TEST REPLACEMENT onnan aana nnnn r 3 17 CRANKSHAFT POSITION SENSOR CPI 3 18 CPS TEST REPLACEMENT um ts Edge Ee 3 18 TEMP MANIFOLD ABSOLUTE PRESSURE SENSOR T MAP 3 19 T MAP TEST REPLACEMENT eege Serben hh nts Einar 3 19 IDLE AIR CONTROL VALVE UNG itis Wate tiee tual patted EE 3 20 IAC TESTA REPLACEMENT ee e EES 3 20 THROTTLE POSITION E GER EE 3 21 TPS RESISTANCE an EE 3 22 TPS TEE REGULATOR hia AE waa ene EE 3 22 CHECKING TPS Le 3 23 TPSADIJUSIMENT ee erie ier ehh ged cere mow AA ws 3 23 TPS REPLACEMENT Age e
21. IGNITION COIL Primary Test Operation Overview The ignition coil is used to provide high voltage to fire the spark plugs When the ignition key is on DC voltage is present in primary side of the ignition coil windings During engine rotation an AC pulse is created within the crankshaft position sensor for each passing tooth on the flywheel The two tooth gap creates an interrupt input signal corresponding to specific crankshaft position This signal serves as a reference for the control of ignition timing The ECU then calculates the time interval between the consecutive pulses and determines when to trigger the voltage spike that induces the voltage from the primary to the secondary coil windings to fire the spark plugs Measure Between Es Connector Pins 1 amp 2 2 amp 3 0 40 Secondary Test Measure Between End Caps MAG Short Wire 1390 Q 15 PTO Long Wire 1545 Q 15 Ignition Coil Tests The ignition coil can be tested by using an ohm meter Use the following illustrations and specification table to test the ignition coil Remove the seat and upper right hand side panel to access the ignition coil Ignition Coil Resistance Readings Test Pin Connection Resistance Between 1 amp 2 Primary Between 2 amp 3 SC Between High Tension MAG 1390 Q 15 Lead Ends PTO 1545 Q 15 Secondary 3 26 9923067 2011 Sportsman 850 Service Manual Copyright 201
22. M 088 L0L00102 Hat 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc 3 40
23. PFA gasket onto fuel pump assembly using care 10 Install fuel pump into fuel tank hold float arm to the pump not to damage gasket or bend float arm body and tilt assembly to ensure float arm does not get caught or bent during installation PFA Nut 11 Gently push down on fuel pump flange ensuring flange is 70 ft Ibs 95 Nm centered Fuel Pump Assembly Koch 2 Roughly align orientation mark on fuel pump with orientation mark on fuel tank to ensure float arm does not get bent or snagged Float Arm CAUTION Failure to align the orientation marks may lead to interferences with the fuel level float arm and cause incorrect function 13 While maintaining downward pressure thread new PFA nut onto fuel tank and hand tighten Use care when starting PFA nut ensuring threads are properly aligned Verify orientation marks are still aligned between fuel pump and fuel tank 3 15 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION 14 Torque PFA nut to specification using the Fuel Pump Service Tool PU 50326 and a calibrated torque wrench Hold or support the fuel tank to prevent it from rotating while tightening the PFA nut 4 E ze 70 5 ft Ibs 95 7 Nm jf Fuel Pump PFA Nut 70 5 ft Ibs 95 7 Nm 15 Verify alignment of fuel pump and tank orientation marks 16 Carefully slide the fuel tank back i
24. RE REGULATOR Operation Overview The fuel pressure regulator maintains the required operating system pressure of 43 psi 3 psi A rubber fiber diaphragm divides the regulator into two separate sections the fuel chamber and the pressure regulating chamber The pressure regulating spring presses against the valve holder part of the diaphragm pressing the valve against the valve seat The combination of atmospheric pressure and regulating spring tension equals the desired operating pressure Any time the fuel pressure against the bottom of the diaphragm exceeds the desired top pressure the valve opens relieving the excess pressure returning the excess fuel back to the tank Fuel Pressure Regulator Test Refer to the Fuel Pump Test procedure Fuel Pressure Regulator Replacement The regulator is a sealed non serviceable assembly If it is faulty the fuel pump assembly must be replaced Refer to the Fuel Pump Replacement procedure 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION FUEL INJECTORS Operation Overview The fuel injectors mount into the Integrated Air Fuel Manifold IAFM and the fuel rail attaches to the top end of them O rings on both ends of the injector prevent external fuel leaks and also insulate it from heat and vibration Pressure Damper Fuel Injectors When the key switch is on the fuel rail is pressurized and the
25. This module kit contains the necessary cables and hardware to communicate between the vehicle ECU and the Digital Wrench diagnostic software Polaris dealers can also order the following separately SmartLink Module PU 47468 Vehicle Interface Cable PU 47469 and PC Interface Cable PU 47470 This kit is available to Polaris dealers through our tool supplier SPX 1 800 328 6657 Nigital Wren Connect to Vehicle Digital Wr cHun Diagnostic Connector Vehicle interface e PU 47469 De Connector for Conmwction to the Digtal Wrench PC K Digital Wreach Magnesi interiace Motaie maom o DE ronas SmartLink Module PU 47468 O TODT IMPORTANT For the most recent information on Wrench PC Digital Wrench software and update downloads please visit the website www polaris diagsys com Digital Wrench Diagnostic Connector The diagnostic connector is located under the front rack in front of the battery as shown 3 3 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION FUEL TANK Exploded View Electrical Connector 8 PFA Nut 70 5 ft Ibs 95 7 Nm Fuel Sender Float Arm Fuel Pump Regulator ea cae Preliminary Filter Tank Vent i PFA Gasket Rollover Valve replace if removed Fuel Tank Assembly Refer to Fuel Pump Replacement for service procedure Fuel Flow Fuel Rail Fuel Injectors
26. To install reverse the previous steps DO NOT apply dielectric grease to the connector as itis a sealed connector Tighten screws to 10 in Ibs 1 1 Nm E T ECU Retaining Screws 10 in Ibs 1 1 Nm IMPORTANT If replacing the ECU you must reflash the new ECU with the correct calibration upon installation and prior to attempting to start the vehicle FUEL PUMP ASSEMBLY Operation Overview An electric fuel pump assembly is used to transfer fuel to the EFI system from inside the fuel tank This assembly includes the fuel pump regulator and fuel gauge sender The pump is rated for a minimum output of 25 liters per hour at 43 psi and has a non serviceable preliminary 60 micron filter Regulator Fuel Gauge Fuel Gauge Float Arm k LC Ee reliminary Filter Fuel Pump 60 micron When the key switch is turned to ON the ECU activates the fuel pump which pressurizes the system for start up The ECU switches off the pump preventing the continued delivery of fuel in these instances e If the key switch is not promptly turned to the Start position e If the engine fails to start e If the engine is stopped with the key switch ON as in the case of an accident 3 11 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION Fuel Sender Test If the fuel gauge reading on the instrument cluster is not working or if the display
27. agsys comfindex php amp Digital Wrench Main Menu Digital Wrench Update 04 27 09 Posted by admin on Friday May 01 14 55 31 COT 5 Home Topic Software Downloads Digital Wrench Version 3 1 04 27 09 is now available No Serial Port Need a USB Adapter for your ney Posted by mike on Monday August 20 13 04 17 CDT Topic Software as become common for computer manufacturers to d to offer a low cost solution from Communications Problems 5 How to Fix Probleme Communicating with the Vehide e DON T DISTURB THE PC While reprogramming is in progress don t move the mouse and don t touch the keyboard The process only takes a few minutes and is best left alone until complete Reprogramming Reflash Procedure If you are not familiar with the reprogramming process review the Reprogramming Reflash Tips before you begin Follow the on screen instructions as you progress through the steps If you encounter a problem always check the On Line help for current tips and information 1 Verify the most current update has been downloaded and loaded into Digital Wrench See Digital Wrench Version and Update ID on page 3 33 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION 2 Connect the SmartLink Module cables to the PC and vehicle See Digital Wrench Diagnostic Connector
28. all the IAC retaining screw and tighten securely 15 Reinstall the airbox attach the intake boot to the intake plenum and tighten the clamp securely 16 Reinstall the breather hose spark plug wires and shift linkage 17 Connect the vehicle harness to the ECU and ignition coil 18 Install the airbox retaining screws and tighten securely 19 Reinstall the front cab side panels and seat see Chapter 9 THROTTLE POSITION SENSOR TPS Operation Overview The throttle position sensor TPS is used to indicate throttle plate angle to the ECU TPS Throttle Mounted on the throttle body and operated directly off the end of the throttle shaft the TPS works like a rheostat varying the voltage signal to the ECU in direct correlation to the angle of the throttle plate This signal is processed by the ECU and compared to the internal pre programmed maps to determine the required fuel and ignition settings for the amount of engine load The correct position of the throttle body stop screw is established and set at the factory DO NOT remove the tamper proof cap to adjust the throttle body stop screw or alter its position in any manner The stop screw controls the air flow calibration of the throttle body Throttle Body Stop Screw Factory Set DO NOT ADJUST 3 21 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION TPS Resistance Tests
29. all the left hand side panel and seat 13 Start engine and test operation 3 24 TPS Replacement NOTE The correct position of the TPS angle on the throttle body is established and set at the factory If the TPS is replaced repositioned or loosened it must be recalibrated Refer to the TPS Adjustment procedure 1 Remove the seat and upper left hand side panel see Chapter 9 Seat and Side Panels 2 Loosen the hose clamp retaining the intake boot to the intake plenum 3 Remove the 4 bolts retaining the intake plenum and throttle body 4 Position the throttle body to access the TPS harness and mounting screws 5 Disconnect the harness from the TPS Disconnect 6 Remove the 2 Phillips head mounting screws and replace the TPS IMPORTANT If replacing the TPS or throttle body you must perform the TPS Adjustment procedure 7 Refer to TPS Adjustment for setting the TPS voltage 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION ENGINE COOLANT TEMPERATURE SENSOR ECT Operation Overview The engine coolant temperature sensor measures coolant temperature The engine temperature sensor is a Negative Temperature Coefficient NTC type sensor as the temperature increases the resistance decreases Coolant passes through the cylinder and by the sensor probe varying a resistance reading which is relayed to the ECU T
30. del e deg wag Rothe tanta alt 3 24 ENGINE COOLANT TEMPERATURE SENSOR EC 3 25 ECT SENSOR TEST REPLACEMENT cots ores onde eo ra cide GE barnes ya 3 25 IGNITION GOIL EE 3 26 IGNITION GOIL EE 3 26 IGNITION COIL AND HT LEAD DEPLACEMENT 3 27 EFI DIAGNOSTICS setae aipate Pio eine kh ied Rita gates a vee DE Poet was 3 28 INSTRUMENT CLUSTER TROUBLE CODE DSP AY 3 28 DIGITAL WRENCH OPERATION e e Eeer EE DEEN CA 3 32 SPECIAL TOOLS DIAGNOSTIC SOFTWARE VERSION 00005 3 32 ECU REPLACEMENT GUIDED DIAGNOSTIC AVAILABLE 4 3 32 DIGITAL WRENCH COMMUNICATION ERRORS 0 0 00000 rrr 3 32 DIGITAL WRENCH DIAGNOSTIC CONNECTOR 20 00 e eee eee 3 33 DIGITAL WRENCH VERSION AND UPDATE ID 0 0 0 errr 3 33 DIGITAL WRENCH SERIAL NUMBER LOCATION eee eeee 3 33 DIGITAL WRENCH UPDATES 2 50624 c cates watoata A eet mice EE ee 3 34 DIGITAL WRENGH FEATURE MAP edd NES ae wears mg ha es 3 35 ENGINE CONTROLLER REPROGRAMMING REFLASH nusssss ssa 3 36 FUEL SYSTEM TROUBLESHOOTING erte eeh d WER e Sw tes somo ete 3 39 EFI SYSTEM BREAK OUT DIAGRAM NEEN RN EN Peed eae tao te 3 40 3 1 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION SPECIAL TOOLS Part Numbers Descriptions PART NUMBER TOOL DESCRIPTION PU 43506 A Fuel Pressure Gauge Kit PS 48762 Fuel Pressure Gauge Adaptor 2201519 A Throttle Positi
31. done manually using the procedures provided 80 of all EFI problems are caused by wiring harness connections Follow a common sense approach when diagnosing a potential EFI issue 1 2 Disconnect the harness at the suspected sensor connector Inspect the connector ends for damage or contamination If damaged repair if contaminated clean Reconnect and check function If problem persists perform a sensor bench test according to the specific sensor requirements if applicable If the sensor bench tests pass disconnect the connector at the ECU and perform a continuity check between the sensor connector and the appropriate pin at the ECU connector all connections for that sensor Wiring resistance should be less than one 1 ohm If the resistance is high or open a wiring harness inspection is required including a thorough inspection of the ECU connector for contamination or damage If the sensor passes and the wiring passes inspection and reconnecting the ECU does not resolve the issue then at that point a known good ECU from another Polaris 850 may be used to test for problem resolution Never attempt to service any fuel system component while engine is running or ignition switch on USE CARE when removing or installing the ECU connector as well as all other harness connections on the unit Properly connect and disconnect the ECU harness to minimize damage to the connector pins and locking mechanism Alt
32. e ratchet or breaker bar loosen and remove the PFA nut Discard the PFA nut a wie kul PFA Nut NOTE Apply downward force on the fuel pump flange while removing the fuel pump PFA nut 3 14 4 Carefully lift the fuel pump out of the fuel tank As the fuel pump assembly is being removed be aware of float arm and pump pre filter Hold the float arm to the pump body as you lift and tilt the pump to ensure that the float arm is not bent when removed from the tank 5 Transfer old fuel pump to a suitable container capable of safely holding fuel The fuel pump will retain some fuel 6 Inspect the inside of the fuel tank for debris may require flashlight and mirror If debris like mud or sand is present fuel tank should be flushed and cleaned out prior to installation of new fuel pump assembly IMPORTANT It is recommended to remove the fuel tank from the vehicle and rinse it with a small amount of clean fuel Do not use water or any other chemicals to remove debris 7 Remove new fuel pump assembly gasket and PFA nut from packaging Use care not to bend float arm during un packaging Do not lift or carry fuel pump assembly by the float arm 8 Use cleaning wipes provided to clean fuel tank surface and threads Remove all debris grease and oil Allow surfaces to dry completely 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION 9 Install new
33. ed turn the key switch off and depress the valve button on the tester to relieve the system pressure Fuel Pump Pressure 43 psi 3 NOTE If the fuel pressure is out of specification replace the fuel pump assembly 5 If the pump did not activate Step 4 disconnect the plug from the fuel pump Connect a DC voltmeter across terminals A and C in the plug on the vehicle harness side Turn on the key switch and observe voltage to ensure a minimum of 7 volts is present NOTE If the voltage was below 7 VDC test battery ignition switch EFI relay and wiring harness 6 Ifthe reading is between 7 and 14 volts turn key switch off and connect an ohmmeter between the terminals A and C in the plug on the pump harness to check for continuity within the fuel pump NOTE If there was no continuity between the pump terminals replace the fuel pump assembly 7 If voltage at the plug was within the specified range and there was continuity across the pump terminals reconnect the plug to the pump making sure you have clean connections Turn on the key switch and listen for the pump to activate NOTE If the pump starts verify you have the correct amount of fuel pressure 8 Ifthe pump still does not operate check ECU operation by plugging in a known good ECU of the same model NOTE If the pump still does not operate replace the fuel pump assembly 9923067 2011 Sportsman 850 Service Manual Copyr
34. eer Wrench DOVNLOADS sew Mam Digital Wrench Version 3 1 Uptates Reveercns carventhy sorted by tithe ate 2 7 Click on the link shown above save the file to your hard disk and then double click the icon to start the update process NOTE Do not run or open the file from where they are Select save and download them to your PC before running the install 8 When the update is complete the version shown on the right side of the Digital Wrench start up screen should match the update you just downloaded Digital Wrench DOVNLOADS CG Ieee oo EER T Cren e Det moe Tir ee ei B eh Ca ca DOUNLOADS r ec Downloads Mam Cotequries IMPORTANT You must already have version 3 1 installed before adding these updates They will not install if you have version 3 0 or older on your PC 3 34 se i Digital Wrench Update 04 27 09 ranis EAEn uiai menea by ec a EE Digital Wrench v Quick Start Selection gt POLARIS Load Curvent Last ASSERT Case Start s New ASSERT Case BO Version 3 1 04 27 09 NOTE Versions and updates are subject to change 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION Digital Wrench Feature Map Enter customer and vehicle Digital Wrench
35. ench screen Start Digital Wrench and click on the Special Tests menu icon red tool box A technician should be familiar with the process and with computer operation in general before attempting to reprogram an ECU The Digital Wrench Engine Controller Reprogramming or Reflash feature allows reprogramming of the ECU fuel and ignition map To successfully reprogram the ECU an Authorization Key must be obtained by entering a Request Code in the box provided on the Reflash Authorization site The Request Code is automatically generated by Digital Wrench during the reprogramming process The Reflash Authorization site is located under the Service and Warranty drop down menu on the dealer website at www polarisdealers com IMPORTANT Failure to follow the reprogramming instructions completely and correctly can result in an engine that does not run Replacement ECUs are programmed as no start and require a reflash for them to work Reprogramming Reflash Tips e BATTERY VOLTAGE The majority of problems with reprogramming can be attributed to a low battery Be sure the battery voltage no load is at least 13 volts and at least 12 5 volts with the key ON Connect a battery charger if necessary to bring voltage level above minimum Fully charge the battery before you attempt to reprogram DEDICATED LAPTOP Best results are obtained using a laptop computer that is dedicated to Digital Wrench A
36. es not read within the specification proceed to the TPS Adjustment procedure If the voltage reading is within specification no adjustment is required TPS Adjustment NOTE This procedure should be performed after you have checked the TPS reading Refer to Checking TPS Reading procedure before making any adjustments 1 Loosen the hose clamp retaining the intake boot to the intake plenum Remove the 4 bolts retaining the intake plenum and throttle body Position the throttle body to access the TPS screws Make sure the TPS Tester harness is still connected to the TPS harness Loosen the TPS mounting screws Rotate the TPS until your voltmeter reads within the specification see Figure 3 20 TPS Output Reading 700 050 Vdc 3 23 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION 7 Retighten the TPS mounting screws and torque to specification TPS Mounting Screws 17 7 in Ibs 2 Nm 8 Verify voltage reading did not change If voltage reading changed repeat steps 5 7 9 Reconnect the vehicle harness to the TPS 10 Reinstall the throttle body and intake plenum Torque bolts to specification Throttle Body Intake Plenum 7 ft Ibs 10 Nm ey T Intake Plenum Bolts 7 ft Ibs 10 Nm 11 Install intake boot to intake plenum and securely tighten the hose clamp 12 Reinst
37. esistance values at each of the following pin locations of the IAC If any of the readings are out of specification replace the IAC IAC Valve Connector IAC Resistance Readings Pins Resistance Pins Resistance 1 2 309 41 20 4 5 309041 20 2 3 30904120 5 6 309041 20 1 3 600 4 2 40 4 6 6090 42 40 3 20 IAC Replacement 1 Remove the seat upper side panels and front cab see Chapter 9 Remove the 2 screws retaining the airbox to the frame 3 Disconnect the main vehicle harness from the ECU and ignition coil located on either side of the airbox 4 Disconnect the shift linkage from the shift lever 5 Remove the spark plug wires 6 Remove the breather hose from the valve cover breather Disconnect 7 Loosen the clamp and remove the intake boot from the intake plenum 8 Remove the airbox assembly from the vehicle 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION 9 Remove the screw retaining the IAC sensor to the frame 10 Move the IAC out from the frame and disconnect the vehicle harness from sensor 11 Remove the 3 Phillips head mounting screws and remove the sensor from the housing 12 Install the new IAC sensor and torque the mounting screws to 17 7 in Ibs 2 Nm T IAC Mounting Screw Torque 17 7 in Ibs 2 Nm 13 Reconnect vehicle harness to IAC 14 Reinst
38. estricted tank vent or routed improperly Failed sensor or disconnected wiring Fuel lines or fuel injectors restricted Symptom Erratic Idle Fuel pump inoperative e Throttle cable incorrectly adjusted Air leak in system ec e Air Leaks dirty injector Intake air leak throttle shaft intake boot gasket or grommet e TPS damaged or misadjusted e Throttle stop screw tampering e Tight valves e Failed sensor or disconnected wiring Belt dragging Dirty air cleaner Rich Mixture Engine worn Spark Plug fouled Symptoms Fouls spark plugs black sooty exhaust smoke rough idle poor fuel economy engine runs rough misses poor performance bog engine loads up backfire Throttle stop screw tampering Air intake restricted inspect intake duct Failed sensor or disconnected wiring Air filter dirty plugged Poor fuel quality old fuel Fouled spark plug TPS setting incorrect Injector failure Failed sensor or disconnected wiring Throttle stop screw tampering 3 39 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION EFI SYSTEM BREAK OUT DIAGRAM
39. ew injector s Install the new injector s and torque the fuel rail mounting screws to 6 9 ft Ibs 8 12 Nm CRANKSHAFT POSITION SENSOR CPS Operation Overview The crankshaft position sensor is essential to engine operation constantly monitoring the rotational speed RPM and position of the crankshaft Removed A ferromagnetic 60 tooth ring gear with two consecutive teeth missing is mounted on the flywheel The inductive speed sensor is mounted 1 0 0 26 mm 0 059 0 010 in away from the ring gear During rotation an AC pulse is created within the sensor for each passing tooth The ECU calculates engine speed from the time interval between the consecutive pulses The two tooth gap creates an interrupt input signal corresponding to specific crankshaft position This signal serves as a reference for the control of ignition timing by the ECU Synchronization of the CPS and crankshaft position takes place during the first two revolutions each time the engine is started This sensor must be properly connected at all times If the sensor fails or becomes disconnected for any reason the engine will stop running CPS Test The crankshaft position sensor is a sealed non serviceable assembly If fault code diagnosis indicates a problem with the CPS test and correct as follows 1 Remove the seat and left hand side panel 2 Locate and disconnect the CPS harness connector on the left side of the vehicle just be
40. gnition cycle causing the MIL to illuminate Diagnostic trouble codes will remain stored in the gauge even if MIL turns off until the key is turned off NOTE If there is a diagnostic problem with the power steering system the power steering MIL will illuminate and blink in place of the check engine MIL Use the Diagnostic Trouble Code Table as a reference refer to the following pages XP EPS MODELS 1 Ifthe trouble code s are not displayed toggle through the LCD display using the SELECT button until the Check Engine MIL icon begins flashing 2 When the Check Engine MIL icon is flashing a set of two numbers will appear on the LCD e The first number can be 2 to 6 digits in length This number equates to the suspected area of fault or the Suspect Parameter Number SPN The second number can be to 2 digits in length This number equates to the fault mode or the Failure Mode Identifier FMI aa 3 If more than one code exists press the MODE button to advance to the next trouble code 4 To exit the diagnostic mode press and hold the MODE button or turn the ignition key OFF once the codes are recorded 3 28 XP X2 TOURING MODELS The reverse override button on the LH control acts as the MODE button when pressed and released quickly 1 If the trouble code s are not displayed use the MODE button to toggle until CK ENG displays on the information display area EZ 7 L
41. hind the LH side panel 2 Temperature and Manifold Absolute Pressure Sensor T MAP Located in the Integrated Air Fuel Manifold AFM 3 Idle Air Control IAC Located in front of the engine under the airbox Crankshaft Position Sensor CPS Located in the top portion of the magneto cover on the front of the engine Fuel Injectors Located in the Integrated Air Fuel Manifold AFM a Fuel Fail ES A 9 EET Le DENI Pressure Ki VK a Valve Pro E Fuel Injector Fuel Rail Fuel Pressure Valve Attached to the top portion of the fuel injectors Located on the PTO end of the fuel rail Fuel Line Quick Connect Located between the injector fuel rail and the fuel tank Fuel Pump Outlet Fuel Rail 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION 8 Fuel Pump Regulator Fuel Gauge Sender Assembly 10 Throttle Position Sensor TPS Located behind the right hand side panel Located on the MAG end front of the throttle body 11 Throttle Body Attached between the AFM and the intake plenum Throttle Body Intake Plenum 12 Ignition Coil Located on the RH side of the airbox The high tension leads are retained by the airbox kal 9 Engine Coolant Temperature Sensor ECT Located in the cylinder head below the thermostat housing just above the throttle body 9923067
42. his signal is processed by the ECU and compared to its programming for determining the fuel and ignition requirements during operation The ECU also uses this signal to determine when to activate the fan during operation ECT Sensor Test To quickly rule out other components and wiring related to the ECT disconnect the harness from the ECT sensor and start the engine After a few seconds the fan should turn on and the Check Engine indicator should display on the instrument cluster This indicates all other components are working properly Refer to Chapter 4 for additional ECT information Polaris dealers can test the sensor by using the Digital Wrench Diagnostic Software dealer only ECT Sensor Resistance Readings Temperature F C Resistance 32 F 0 C 5 9k Q 5 68 F 20 C 2 5k Q 5 176 F 80 C 323 Q 5 212 F 100 C 186 Q 5 ECT Sensor Replacement 1 Drain coolant to level below sensor 2 Disconnect the ECT sensor from engine harness Remove the T MAP sensor to allow access to the ECT sensor mal mhhh R Mla lt LLit 3 Remove and replace the sensor applying a light coating of thread sealant to aid installation 4 Torque the ECT sensor to specification E T ECT Sensor Torque 17 ft Ibs 23 Nm 3 25 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION
43. hough every precaution has been taken to prevent water intrusion failure avoid direct water or spray contact with system components Do not disconnect or reconnect the wiring harness connector to the ECU or any individual components with the ignition on This can send a damaging voltage spike through the ECU Do not allow battery cables to touch opposite terminals Never start the engine when the cables are loose or poorly connected to the battery terminals Never disconnect battery while engine is running Always unplug ECU from the wire harness before performing any welding on the unit 3 5 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION EFI SYSTEM LAYOUT Exploded View Electronic Control Unit ECU Temperature Manifold Absolute Pressure Sensor T MAP Idle Air Control IAC Crankshaft Position Sensor CPS Fuel Injectors Fuel Rail Fuel Line quick connect Fuel Pump Regulator Fuel Gauge Sender inside fuel tank Engine Coolant Temperature Sensor ECT 10 Throttle Position Sensor TPS 11 Throttle Body 12 Ignition Coil OO OO JO Om P ON ch Located in the Fuel Tank Asm 3 6 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION EFI COMPONENTS Identification Location 1 Electronic Control Unit ECU Attached to the air box located be
44. ight 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION Fuel Tank Removal IMPORTANT Syphon as much fuel from the tank as possible before attempting to remove it from the ATV 5 Always wear safety goggles when working with A WARNING high pressure or flammable fluids Failure to do so could result in serious injury or complications Remove the seat and upper side panels see Chapter 9 Disconnect the negative battery cable Remove the 4 push rivets from each front mud guard and remove the guards from the vehicle see Chapter 9 Remove the front rack or storage box assembly see Chapter 9 Remove the front cab assembly see Chapter 9 IMPORTANT Be sure to cover the fuel tank inlet with a shop towel prior to front cab and fuel tank removal see Chapter 9 Front Cab 6 7 8 Remove the 4 screws from the bottom of the right hand footwell Remove the 2 fuel tank mounting screws located on the upper portion of the fuel tank Ensure that static has been discharged from you by touching a ground source such as the engine or frame 9 Disconnect the fuel pump electrical harness 10 While holding a shop towel over the fuel line connector disconnect the quick connect fuel line from the fuel pump AA CAUTION It is possible for pressurized fuel to be present when disconnecting the fuel line It is recommended to allow the vehicle to sit for a period of one hour afte
45. l start up and or any time the system has been disassembled If the EFI system is completely empty of fuel or has been disassembled and repaired 1 Cycle the key switch from OFF to ON 6 times waiting for approximately 3 seconds at each ON cycle to allow the fuel pump to cycle and shut down 2 Once step is completed turn the key switch to START until the engine starts or 5 seconds has passed 3 If the engine failed to start repeat step 1 for 2 more cycles and attempt to start the engine If the engine fails to start a problem may still exist and should be diagnosed NOTE Accurate testing of EFI recommended utilizing the Digital Diagnostic Software dealer only components is Wrench 3 9 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION ELECTRONIC CONTROL UNIT ECU Operation Overview The ECU is the brain or central processing computer of the entire EFI fuel ignition management system During operation sensors continuously gather data which is relayed through the wiring harness to input circuits within the ECU Signals to the ECU include ignition on off crankshaft position and speed RPM throttle position engine coolant temperature intake air temperature intake manifold air pressure and battery voltage The ECU compares the input signals to the programmed maps in its memory and determines the appropriate fuel
46. laptop that is used by a variety of people and in several applications around the dealership is more likely to cause a reprogramming problem than one dedicated to Digital Wrench diagnostics only OBTAINING THE LATEST UPDATE Reprogramming updates are provided periodically and contain the most recent calibrations see Digital Wrench Updates CLOSE NON ESSENTIAL PROGRAMS Polaris recommends that you DO NOT install non essential programs on a Service Department laptop Camera detection software Virus Scanners Tool Bars etc may clog up memory if running in the background and make it harder for the diagnostic software to operate 3 36 e KNOW THE PROCESS If you are not familiar with the entire reprogramming process review the HELP section of the diagnostic software before you attempt reprogramming Click on the on the tool bar or press F11 The information in the on line help is the most current and complete information available This should be your first step until you are familiar with the process e COMMUNICATION PROBLEMS If you have had problems communicating with a vehicle while performing diagnostic functions do not attempt reprogramming until the cause has been identified and fixed Check all connections and be sure battery voltage is as specified Proceed to http polaris diagsys com for specific information and FAQs on how to troubleshoot communication problems Address L http polaris di
47. lated area system pressure has been relieved before disassembly 3 2 Fuel Pressure Gauge Kit PU 43506 A IMPORTANT The EFI fuel system remains under high pressure even when the engine is not running Before attempting to service any part of the fuel system the pressure must be relieved The Fuel Pressure Gauge Kit has an integrated pressure relief valve that can be used to bleed off pressure Adaptor shown is included with kit Fuel Pressure Gauge Adaptor PS 48762 Used in conjunction with PU 43506 A to check fuel pressure 7 16 20 Schrader Throttle Position Sensor Tester 2201519 A This tester allows the use of a digital multi meter to test TPS function and perform the TPS Adjustment procedure 2201519 A 547927 marked 4010264 Use a NEW 9V Battery PU 47466 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION Digital Wrench Diagnostic Software Digital Wrench Download Website PU 47063 A Located at www polaris diagsys com This dealer only software installs on laptop computers equipped Digital Wrench with a CD drive and serial port connection and is designed to replace multiple shop tools often used to test EFI components It also includes step by step diagnostic procedures to aid technician repair and troubleshooting Digital Wrench SmartLink Module Kit PU 47471
48. ld absolute pressure sensor T MAP is a non serviceable item If it is faulty it must be replaced This sensor requires a5 Vdc input to operate therefore the T MAP sensor should only be tested using the Digital Wrench Diagnostic Software dealer only T MAP Replacement 1 Disconnect the sensor from the main harness 2 Using a 10 mm wrench remove the retaining bolt and sensor 3 Install the new sensor using a light coating of oil on the O ring to aid installation 4 Torque the retaining bolt to specification E T T MAP Retaining Bolt Torque 35 53 in Ibs 4 6 Nm 3 19 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION IDLE AIR CONTROL VALVE IAC Operation Overview The Idle Air Control IAC is used to stabilize the idle quality of the engine at cold start up and after warm up operations Mounted in front of the engine the IAC contains 1 stepper motor which receives varying voltage signal pulses from the ECU These pulses determine the IAC plunger setting thereby controlling the amount of air bypassing the closed throttle body for idle control If the IAC is disconnected or inoperative it will remain at it s last operated position IAC Test The IAC is a non serviceable item If it is faulty it must be replaced It can be bench tested using the following method Set your meter to read Ohms Check the r
49. llows the technician to perform the following tests and observations e View or clear trouble codes e Analyze real time engine data e Reflash ECU calibration files Special Tools also refer to page 3 2 e Perform guided diagnostic procedures e Create customer service account records e Perform output state control tests on some models Digital Wrench Diagnostic Kit PU 47063 A PU 47063 A listed above INCLUDES Digital Wrench Software PU 48731 Standard Interface Cable PU 47151 SmartLink Module Kit PU 47471 Fuel Pressure Gauge Kit PU 43506 A Fuel Pressure Gauge Adapter Fluke 73 Digital Multi Meter or Fluke 77 DMM PS 48762 PV 43546 Fluke 77 PV 43568 Laptop or Desktop Computer USB Serial Adaptor Saelig RS 232 Commercially Available refer to diagnostic software user manual or HELP section for minimum requirements Diagnostic Software Version Always use the most current version of the Digital Wrench software to ensure you have the latest updates or enhancements New reprogramming files and guided diagnostic procedures are added to these updates as they become available For information on how to determine if you have the latest update available refer to Digital Wrench Version and Update ID ECU Replacement Although the need for ECU replacement is unlikely a specific replacement procedure is required to ensure that all essential data contained within the
50. low the ECU Egy 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION 3 Connect an ohmmeter between the pin terminals as shown A resistance value of 860 10 at room temperature 20 C 68 F should be obtained CPS Connector Measure resistance at these two pins 4 If resistance is correct check the mounting toothed ring gear damage runout etc and flywheel key Crankshaft Position Sensor 860 Q 10 20 C 68 F CPS Replacement 1 Disconnect sensor harness connector see CPS Test 2 Using a6 mm hex wrench remove the retaining bolt and remove the sensor from the magneto cover 3 Install the new sensor using a light coating of oil on the O ring to aid installation 4 Torque the retaining bolt to specification E T CPS Retaining Bolt Torque 7 ft Ibs 10 Nm TEMP MANIFOLD ABSOLUTE PRESSURE SENSOR T MAP Operation Overview Mounted on the IAFM the temperature and manifold absolute pressure sensor T MAP performs two functions in one unit Air passing through the intake is measured by the T MAP and relayed to the ECU These signals comprised of separate air temperature and manifold absolute pressure readings are processed by the ECU and compared to its programming for determining the fuel and ignition requirements during operation T MAP Test The temperature and manifo
51. mbers in a request code Reprogramm gt POLARIS TOETER Authorization Key goes here after Site Enter the Authorization obtained from the dealer website DO NOT SHUTDOWN THE SOS COMPLETE OR THE AUTHORIZATION KEY WILL As LOST E Engine Controller Request Code BBITHGHJJOKK Authorization Key Copy Request Code to obtain Authorization Key 2009 Sportsman XP 550 EPS Status NOTE Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen 3 37 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION 9 Go to www polarisdealers com and click on ReFlash 12 An Authorization Key will appear in the upper left corner Authorization from the Service and Warranty drop of the screen Copy CTRL C this key exactly as it down menu appears D e Re emer EEN Gor GES SI D CS Im E me ii ep e Im om we Pie ep mp s d torim Baie Crena e e e ptm i 9 nn a e on Oconputmacascn LI Ra Segepettge neuen Je SEET POLARIS a 2 COMPUTERCHECK MS E gt POLARIS Ekz News Forms A Links Special Alerts lom EXACTLY 2s shown into the Digital Wrench Start Ove 2000 Diagnostic Systems Associates Authorization Key 10 Enter or paste CTRL V the Request Code into the box 13 Enter or paste CTRL V the Authorization Key in the box
52. nal weeping around the injector body The loss of system pressure from the leakage can cause hot restart problems and longer cranking times Injector problems due to dirt or clogging are unlikely due to the design of the injectors the high fuel pressure the use of filters and the detergent additives in the gasoline Symptoms that could be caused by dirty clogged injectors include rough idle hesitation stumble during acceleration or triggering of fault codes related to fuel delivery Injector clogging is usually caused by a buildup of deposits on the director plate restricting the flow of fuel resulting in a poor spray pattern Some contributing factors to injector clogging include dirty air filters higher than normal operating temperatures short operating intervals and dirty incorrect or poor quality fuel Cleaning of clogged injectors is not recommended they should be replaced Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem Fuel Injector Test If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem Check as follows e Remove the seat left hand side panel and disconnect the fuel injector s e Using an ohmmeter test for continuity by placing the test leads on each pin of the injector e Resistance specification is 12 Q 5 20 C 68 F Fuel Injector Resistance Specification 12 Q 5 20 C 68 F
53. nto position Ensure vent line has not been pinched during installation of fuel tank NOTE Take care not to damage the Idle Air Control IAC valve upon fuel tank installation 17 Refer to Fuel Tank Installation to complete the repair Fuel Tank Installation 1 Reinstall the fuel tank assembly through the right side Be sure the tabs on the bottom of the fuel tank are sitting in the slots of the support bracket 2 Connect the fuel line to the fuel pump outlet Press in white retainer to engage the tabs SCH 3 16 IMPORTANT Be sure to engage the white retainer on fuel line until it snaps into place Pull on fuel line lightly to confirm connection 3 Connect the fuel pump electrical harness 4 Reinstall the vent line to the tank fitting 5 Install the 2 fuel tank mounting screws and tighten securely 6 Install the 4 screws into the bottom portion of the right hand footwell 7 Remove the shop towel from the fuel tank inlet and reinstall the front cab assembly see Chapter 9 Front Cab 8 Connect the fuel fill hose and tighten hose clamp securely 9 Reinstall the front rack or storage box assembly see Chapter 9 10 Install the front mud guards see Chapter 9 Mud Guards 11 Reconnect the negative cable to the battery 12 Install the upper side panels and seat see Chapter 9 13 Test the fuel pump by turning on the key and listening for the pump to activate FUEL PRESSU
54. on Sensor TPS Tester PU 47466 TPS Tester Wire Harness 547927 TPS Tester Regulator Digital Wrench Diagnostic Software Includes most recent version of software w serial number standard interface cable and SmartLink Module Kit PU 47063 A Digital Wrench SmartLink Module Kit PU 47471 PU 47470 PU 47469 PU 47468 Digital Wrench PU 47470 PC Interface Cable Digital Wrench Vehicle Interface Cable Digital Wrench SmartLink Module PU 47469 PU 47468 A WARNING Gasoline is extremely flammable and explosive under certain conditions EFI components are under high pressure Verify Never drain the fuel system when the engine is hot Severe burns may result Do not overfill the tank The tank is at full capacity when the fuel reaches the bottom of the filler neck Leave room for expansion of fuel Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time Do not smoke or allow open flames or sparks in or near the area where refueling is performed orwhere gasoline is stored If you get gasoline in your eyes or if you should swallow gasoline seek medical attention immediately If you spill gasoline on your skin or clothing immediately wash with soap and water and change clothing Always stop the engine and refuel outdoors or in a well venti
55. original ECU is transferred to the replacement ECU Refer to procedure and carefully follow all instructions provided in Digital Wrench Guided Diagnostic Available Guided diagnostics are available within Digital Wrench for all supported Trouble Codes that is any fault that will turn on the Check Engine indicator In addition guided diagnostics are also available for many other electrical sub systems 3 32 Diagnostic procedures are added to subsequent versions of Digital Wrench as they become available Check your release version often and upgrade when available to be sure you are using the most current software available Digital Wrench Communication Errors If you experience problems connecting to a vehicle or any Digital Wrench related problem visit the Digital Wrench Knowledge Base for the most current troubleshooting information FAQs downloads and software updates at http polaris diagsys com Digital Wrench 2 m Procedures amp Solutions Errors and Troubleshooting Frequently Asked Questions 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION Digital Wrench Diagnostic Connector The diagnostic connector is located under the front rack or storage box in front of the battery as shown Follow these steps to connect the diagnostic interface cable to the vehicle to allow Digi
56. r shutting off the engine before servicing the fuel pump This allows the exhaust to cool and fuel pressure to drop NOTE A small amount of fuel may come out of the fuel line or tank Properly drain fuel into a suitable container 11 If replacing the fuel pump carefully pull the fuel tank out far enough to service the fuel pump see Fuel Pump Replacement procedure If removing fuel tank assembly proceed to the next step 12 Remove the vent line from the fitting on top of the fuel tank 13 Carefully pull the fuel tank out the right side of the ATV 3 13 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION Fuel Pump Replacement 1 Slide the fuel tank out to allow enough access to service the fuel pump see Fuel Tank Removal procedure NOTE Take care not to damage the Idle Air Control IAC valve upon fuel tank removal 2 Be sure the top of the fuel tank is clean If it requires cleaning hand wash the top of the tank to ensure no debris will enter the fuel system when the fuel pump is removed Clean this area CAUTION Failure to clean area around fuel pump may lead to debris entering the fuel tank during service Excessive debris in fuel tank may cause premature wear of fuel pump and or clogging of internal fuel filters 3 Place the Fuel Pump Service Tool PU 50326 over the fuel pump PFA nut Using a 1 2 driv
57. reading differs in large comparison to the fuel in the tank perform a resistance test on the fuel sender Disconnect the fuel pump sending unit connection and measure the resistance between the Purple and Brown wires If out of specification replace the fuel pump assembly Fuel Sender Resistance Specifications Full 6410 Empty 90 4 5 Q Fuel Pump Test NOTE If determined faulty the fuel pump can be replaced as an assembly If a fuel delivery problem is suspected make certain the pump is being activated by the ECU and EFI relay all electrical connections are properly secured the 20A EFI fuse is good anda minimum of 7 0 volts is being supplied AA CAUTION Fuel is extremely flammable and may cause severe burns injury or death Do not use any device that produces a flame or electrical devices that may spark around fuel or fuel vapors 1 Couple the Fuel Pressure Gauge Adaptor PS 48762 to the Fuel Pressure Gauge Kit PU 43506 A PU 43506 A Relief Valve Adaptor shown is included with kit 7 16 20 Schrader 3 12 2 Locate the fuel pressure valve attached to the fuel rail 3 Remove the black cap and attach the fuel pressure gauge kit and adaptor to the pressure valve Route the clear hose into a portable gasoline container or the vehicle s fuel tank 4 Turn on the key switch to activate the pump and check the system pressure on the gauge If system pressure of 43 psi 3 is observ
58. t as shown and verify the voltage reads 4 99 5 01 Vdc If the reading is low replace the 9 volt battery Red Probe Black Probe Should Read 4 99 5 01 Vdc Checking the 9V Battery TPS Reference Voltage 5 Vdc Input IMPORTANT Always use a fresh 9 Volt battery 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc ELECTRONIC FUEL INJECTION Checking TPS Reading 1 Remove the seat and upper left hand side panel see Chapter 9 Seat and Side Panels Assemble the TPS Tester according to the instructions Refer to TPS Tester Regulator for proper set up and testing Verify the 9 volt tester battery is new Disconnect vehicle harness from TPS Plug the TPS Tester harness into the TPS Set your voltmeter to read DC Volts Insert the red and black voltmeter probes into the test ports see Figure 3 20 Move the throttle open and closed slowly while reading the display The voltage should increase and decrease smoothly without any jumps when the throttle is applied If voltage varies with throttle movement continue on to the next step If the sensor did not function correctly replace it Allow the throttle lever to rest in the idle position The voltmeter should read within the specification Red Probe Black Probe Should Read 700 050 Vdc Checking TPS Reading Figure 3 20 TPS Output Reading 700 050 Vdc If the voltage do
59. tal Wrench use 1 Assemble the SmartLink Module and attach the PC Interface Cable to your laptop see page 3 3 2 Remove the protective cap from the Digital Wrench connector 3 Connect the Vehicle Interface Cable to the Digital Wrench diagnostic connector 4 Turn the ignition key to the ON position select the appropriate vehicle and wait for the status to display Connected in the lower left corner of the screen 5 Once connected proceed with using Digital Wrench Digital Wrench Version and Update ID Knowing what Digital Wrench version and update is installed will help determine which updates are required NOTE Versions and updates are subject to change 1 Open the Digital Wrench software Locate the version ID shown on the lower right side of the Digital Wrench start up screen Digital Wrench w gt POLARIS Quick Start Selection es E E3 ZE New ASSERT Case Version 3 1 03 13 09 2 In this case the version number is 3 1 with a 03 13 09 update Proceed to http polaris diagsys com to see if a newer update is available Afren rr Pr wwii Gibi DOVNLOADS eent r Att Zement e Pr Tan Aen Digital Wrench Update 04 27 09 bel Fences surrenity sorted by De Ja aam Secrets Cen en 3 In this case a newer update 04 27 09 is available and should be downloaded before using Digital Wrench
60. tank At the engine fuel is fed through the fuel rail and into the injectors which inject into the intake ports The ECU controls the amount of fuel by varying the length of time that the injectors are on This can range from 1 5 8 0 milliseconds depending on fuel requirements The controlled injection of the fuel occurs every other crankshaft revolution or once for each 4 stroke cycle The total amount of fuel needed for one firing of a cylinder is injected during each cycle When the intake valve opens the fuel air mixture is drawn into the combustion chamber ignited and burned The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for intake air temperature manifold absolute pressure load engine temperature speed RPM and throttle position These primary signals are compared to the programming in the ECU computer chip and the ECU adjusts the fuel delivery and ignition timing to match the values During operation the ECU has the ability to re adjust temporarily providing compensation for changes in overall engine condition and operating environment so it will be able to maintain the ideal air fuel ratio During certain operating periods such as cold starts warm up acceleration etc a richer air fuel ratio is automatically calculated by the ECU Initial Priming Starting Procedure NOTE The injection system must be purged of all air prior to the initia
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