Home

2011-2012 RANGER 800 XP / HD / CREW / 6x6

1. HE E ope Adda Waste 10 38 STARTER SOLENOID BENCH TEST 10 39 STARTER SOLENOID OPERATION 10 39 STARTER EXPLODED VIEW 0 10 40 STARTING SYSTEM TESTING FLOW CHART ELECTRONIC POWER STEERING EPS EPS OPERATION ertt oem Tee ee eA bet vy spa kiss 10 42 PROPER EPS SYSTEM DIAGNOSING 10 42 EPS SYSTEM BREAKOUT MODEL YEAR 2011 10 43 EPS SYSTEM BREAKOUT MODEL YEAR 2012 10 44 EPS TROUBLESHOOTING EPS NON FUNCTIONAL WITH MIL ON 10 45 EPS TROUBLESHOOTING EPS NON FUNCTIONAL WITH MIL OFF 10 46 EPS TROUBLESHOOTING USING DIGITAL 10 47 ELECTRICAL SYSTEM BREAKOUTS CHARGING SYSTEM hisi ass ie be hee Shae aE Ree 10 48 COOLING FAN chere REDE asao qowi S ds 10 48 CONSTANT BATTERY POWER 10 49 KEY ON BATTERY POWER 0 000000 0 cece eee 10 50 ELECTRONIC POWER STEERING EPS 10 51 ENGINE START STARTER 10 52 AWD TUBE ets ti iia laces s cette nae et ua eerte Tete en e 10 53 VEHIGLE SPEED SENSOR a RE RR OE Eq 10 54 ECM WAKE UP FUEL PUMP AND LEVEL IGNITION 10 55 LI
2. ELECTRICAL Relay Operation Located in the fuse box under the hood the relays assist with component operation like the cooling fan fuel pump EFI system drive system and EPS CHASSIS RELAY provides power to the following systems Lights Headlights Taillights Drive AWD TURF Accessory 12V Receptacles Accessory Options CHASSIS RELAY COLOR FUNCTION BUSS Bar 12 Vdc constant Red battery voltage fusible link protected Brown Relay coil ground 12 Vdc power input from key Orange switch to enable relay Provides 12 Vdc power for lights White drive and accessory circuits ECM RELAY provides power to the following systems Fuel Injectors Cam Phase Sensor Ignition Coil Fan Relay Fuel Pump Relay ECM RELAY COLOR FUNCTION Red White 20 Amp fuse protected 12 Vdc constant battery voltage Dark Green Yellow ECU ground input to enable relay 20 Amp fuse protected 12 Vdc Red White constant battery voltage Provides 12 Vdc power for EFI Red Dark Blue OPE system circuits 10 26 FAN RELAY provides power to the following system Fan Motor FAN RELAY COLOR FUNCTION Red 20 Amp circuit breaker protected 12 Vdc constant battery power Orange White ECU ground input to enable relay BUSS Bar 12 switched Red Dark Blue power from ECM relay Provides 12 Vdc power for fan Orange Black i
3. Yes Meter Setting DC Volts With the transmission in Neutral start the engine and increase RPM to between 3000 and 4000 Read battery voltage withthe Yes gt multitester Readings should increase to between 13 0 and 14 6 V D C Do they NOTE Disconnect all accessories Check Key off Current Draw No Check for owner modification and discuss operating habits The battery Meter Setting DC Amps will continually discharge if operated Perform system Break Even Amperage Yes below the Break Even RPM Con test outlined in this chapter tinued problems would call for battery Does charging occur as specified inspection No Ohm stator wires if bad replace stator if good continue with alternator output test Inspect the wiring harness between Meter Setting AC Volts the panel and the stator for Disconnect the Yellow wires from the regulator damage If no damage is found rectifier Using a multitester perform an Alternator No gt remove the recoil and flywheel Output test See test procedure on Page 10 29 Inspect the flywheel magnets stator coils and stator wires for damage Does output meet specification Repair or replace any damaged components Yes Y Meter Setting DC Volts Reconnect the alternator wires Measure between the Red and Black terminals with the harness disconnected Battery voltage must be present
4. Connect the leads together and record the resistance The resistance of the component is equal to tested value minus the lead resistance Become familiar with the operation of your meter Be sure leads are in the proper jack for the test being performed i e 10A jack for current readings Refer to the Owner s Manual included with your meter for more information Voltage amperage and resistance values included in this manual are obtained with a Fluke 77 Digital Multimeter PV 43568 This meter is used when diagnosing electrical problems Readings obtained with other meters may differ Pay attention to the prefix on the multimeter reading K M etc and the position of the decimal point For resistance readings isolate the component to be tested Disconnect it from the wiring harness or power supply 10 3 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL SWITCHES CONTROLS Brake Light Switch The brake light switch is located on the master cylinder behind the front left wheel well panel 1 Remove the front left wheel well panel to access the back side of the master cylinder 2 Disconnect the wire harness from the brake switch Brake Switch BEES 3 Connect an ohmmeter across switch contacts Reading should be infinite OL 4 Apply foot brake and check for continuity between switch contacts If there is no continuity or if resistance is gre
5. LOCATED UNDER 8 8 FUSE RELAY BLOCK RD WH ON ECM CHASSIS M d EE Tt S BN RD WH De ami RD WH 10 23 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Overview Operation Model Year 2012 Located in the fuse box under the hood the fuses provide overload protection for wiring and components such as the instrument cluster ECU EFI system main harness lights and accessories The relays assist with component operation like the cooling fan fuel pump EFI system and drive system A separate 20 amp circuit breaker located near the fuse relay box protects the fan motor circuit NOTE 2012 models with EPS have a separate electrical system which includes a 30 amp fuse and relay Refer to EPS System Breakout 2012 for EPS electrical component details RELAY TOP VIEW TOP VIEW l OF RELAY ns TT Us be CIRCUIT BREAKER 20 AMP a FAN CIRCUIT FAN CIRCUIT RD BREAKER IN BREAKER OUT RD RD BK 24 RD FUSIBLE SPLICE 1 RELAY FUSE BLOCK REVERSE POLARITY DIODE BUSS CAVITIES C7 CS C3 BUSS CAVITIES A7 AS BUSS CAVITIES DS D7 of o2 RD BU eX Ww lt 0G Bk p RD DB RD DB om BN eo i Ne RD GN of e 06 DG YE e amp 0 6 Do 06 WH eo RD WH RD f5 DG YE 9
6. RD WH 0 10 24 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Fuse Box Detail aub cmd FUSE RELAY BLOCK AS FUEL PUMP RELAY COIL B BS FUEL PUMP RELAY POWER IN B3 EPS RELAY POWER IN B4 FUEL PUMP RELAY COIL B B2 EPS RELAY COIL B A4 FUEL PUMP RELAY PWR OUT A2 EPS RELAY PWR OUT TOP VIEW OF RELAY pm OF RELAY us VIEW Model Year 2011 Only D2 FUEL PUMP FUSE OUT D3 FUEL PUMP FUSE IN C2 ACC FUSE OUT C3 ACC FUSE IN A7 FAN RELAY COIL B B7 FAN RELAY POWER IN B6 FAN RELAY COIL B AB FAN RELAY PWR OUT Model Year 2011 Only D4 EPS FUSE OUT L DS EPS FUSE IN C4 DRIVE FUSE OUT C5 DRIVE FUSE IN VIEW OF RELAY x E x AS ECM RELAY COIL BS ECM RELAY POWER IN B8 ECM RELAY COIL B A8 ECM RELAY PWR OUT D6 ECM FUSE OUT 07 FUSE IN C6 LIGHTS FUSE OUT C7 LIGHTS FUSE IN CS CHASSIS RELAY COIL B D9 CHASSIS RELAY POWER IN D8 CHASSIS RELAY COIL B C8 CHASSIS RELAY PWR OUT E VIEW VIEW electrical problems OF RELAY OF RELAY wis MIL i A B D IMPORTANT All relays PN 4011283 located in fuse box AS BS are the same and can be swapped out to help diagnose C3 09 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc
7. electrical system For this reason a battery capacity or load test should be conducted whenever poor battery performance is encountered This is the best test of battery condition under starting load Use a load testing device that has an adjustable load Apply a load of three times the ampere hour rating At 14 seconds into the test check battery voltage A good 12V battery will have at least 10 5 Volts If the reading is low charge the battery and retest Battery Conductance Analyzer Conductance describes the ability of a battery to conduct current A conductance tester functions by sending a low frequency AC signal through the battery and a portion of the current response is captured from this output a conductance measurement is calculated Conductance testing is more accurate than voltage specific gravity or load testing Authorized Polaris dealers distributors are required to use the conductance analyzer when testing 12V Polaris batteries Polaris MDX 610P Conductance Analyzer Polaris MDX 610P SPX PN PU 50296 10 34 Charging Procedure 1 Remove the battery to prevent damage from leaking or spilled acid during charging 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific gravity to 1 270 or greater 3 Install battery in vehicle Coat threads of battery bolt with a corrosion resistant dielectric grease
8. form on the plates reducing the efficiency and service life of the battery Specific Gravity Test A tool such as a Battery Hydrometer PN 2870836 can be used to measure electrolyte strength or specific gravity As the battery goes through the charge discharge cycle the electrolyte goes from a heavy more acidic state at full charge to a light more water state when discharged The hydrometer can measure state of charge and differences between cells in a multi cell battery Readings of 1 270 or greater should be observed in a fully charged battery Differences of more than 025 between the lowest and highest cell readings indicate a need to replace the battery Battery Hydrometer PN 2870836 OPEN CIRCUIT VOLTAGE State of Charge YuMicron Type 100 Charged 12 70 V 75 Charged 12 50 V 50 Charged 12 20 V 25 Charged 12 0 V 0 Charged 11 9 V or less SPECIFIC GRAVITY State of Charge YuMicron Type 100 Charged 1 275 75 Charged 1 225 50 Charged 1 175 25 Charged 1 135 0 Charged 1 115 or less At80 F NOTE Subtract 01 from the specific gravity reading at 40 F 10 33 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Load Test A battery may indicate a full charge condition in the OCV test and the specific gravity test but still may not have the storage capacity necessary to properly function in the
9. operation FUEL PUMP RELAY provides power to the following system Fuel Pump FUEL PUMP RELAY COLOR FUNCTION 10 Amp fuse protected 12 Vdc Red Light Green battery voltage Dark Green Yellow ECU ground input to enable relay BUSS Bar 12 Vdc switched power from ECM relay Red Dark Blue Provides 12 Vdc power for fuel Red Light Blue pump operation EPS RELAY provides power to the following system Electronic Power Steering Unit EPS RELAY COLOR FUNCTION 30 Amp fuse protected 12 Vdc Red constant battery voltage Brown Relay coil ground Orange 12 Vde power input from key switch to enable relay Provides 12 Vdc power for EPS Orange operation NOTE The EPS Relay on Model Year 2012 vehicles is mounted separately outside the fuse relay box to the electronic power steering harness 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL REAR DIFF SOLENOID RELAY provides power to the following system Rear Differential Solenoid REAR DIFF SOLENOID RELAY COLOR FUNCTION 20 Amp fuse protected 12 Vdc battery voltage Dark Green White ECU input to enable relay Red Dark Green Brown Relay coil ground Red Relay switched power to operate the Rear Diff Solenoid Ground to energize the Rear Diff Blue Solenoid NOTE The R
10. turning and then Connect Digital wrench and read Power Steering Error Codes If Inverter Temperature Error Code is present replace Power Steering Module If error is not present Module is OK EPS inverter temperature can be checked using Digital wrench pins with key on If voltage is low investigate and correct cause If voltage at pins is correct check all connections for corrosion damage and tightness Check pin 3 on 8 pin connector for 12V signal with key on 10 47 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL ELECTRICAL SYSTEM BREAKOUTS Charging System Fuse link Regulator ENGINE STATOR STATOR LOCATED UNDER FLYWHEEL ON ENGINE TERMINAL BLOCK 1 B BATTERY Cooling Fan TERMINAL BLOCK 1 B BATTERY ECM MONITORS COOLANT TEMPERATURE PIN 244 AND SWITCHES PIN 204 TO GROUND ENERGIZING THE FAN RELAY TO RUN THE FAN MOTOR WHEN NEEDED COOLANT TEMP ECM 244 SENSOR Fuse link EFI REL COIL FAN REL COIL 10 48 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Constant Battery Power KEY ON ACTIVATES CHASSIS EPS RELAYS TERMINAL 20A BR FAN BLOCK 1 B FAN RELAY WAKES UP ECM L vcre rk me v e re hf oe CEA T OPE Poa gets TCR 30A FUSE EPS Model Year
11. 1 Measure the resistance value of each of the three stator legs Y1 to Y2 Y1 to Y3 and Y2 to Y3 Each NOTE If one or more of the stator leg output AC voltage varies significantly from the specified value the stator may need to be replaced test should measure 0 190 15 RPM Reading AC Voltage VAC Reading 1300 18 25 Connect Meter Tes Leads Ohms Reading 3000 42 25 Battery Charge Coil Y1 to Y2 0 190 15 5000 64 25 Battery Charge Coil Y1 to Y3 0 190 15 a Regulator Rectifier Battery Charge Coil Y2 to Y3 0 190 15 NOTE If there are any significant variations in ohm readings between the three legs it is an indication that one of the three stator legs maybe weak or failed TEST 2 Resistance Value of Each Stator Leg to Ground 1 Measure the resistance value of each of the stator legs to ground Y1 to Ground Y2 to Ground Y3 to Ground Each test should measure Open Line OL Connect Meter Test Leads To Ohms Reading Y1 Y2 Open Line Battery Charge Coil Ground Infinity NOTE Any measurement other than Infinity open will indicate a failed or shorted stator leg TEST 3 Measure AC Voltage Output of Each Stator Leg at Charging RPM 1 Setthe selector dial to measure AC Voltage 2 Start the engine and let it idle 3 While holding the engine at a specified RPM separately m
12. 2012 SPLICE B UNSW SPEEDO FUSE ECM SWITCH B EFI REL Sa PE U COIL S D 20AF EFI 9 EFI RELAY 7 5 30A FUSE EPS Model Year 2011 CHASSIS RELAY 10 49 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Key On Battery Power 8 V ACL 1109 NOILINSI SMHOLO3fNI W23 1313 esz 9 W03 dn ayvM 1109 AV 133 602 WO3 1109 1109 738 dWnd 143 coc noa 109 ANNOYS 7100 ANNONO SISSVHO Woa dN S3xVM SAV T3M Sd3 SISSVHO SALVAILOV NO A3 AHOSS3OOV SS3OOV M90 18 IVNIINSH3 L 3j VOZ eosng yosna VTI3H osna SISSVHO LLOZ 1 J9poIN YOSNAS sa3 AV 133 3385 Sd3 35 4 voe 1 Hs a 4 4 VOZ Sd3 f 1soNovia HY 4 VOL Oqaads 2102 1 I pOW AV 133 Sd3 g M2018 Sd3 3Snd voe TWNIWYSL S 2 6 s n g INO3 3S r1d QSHOLIMSNN 9 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Electronic Power Steering EPS INO3 MYOMLAN NO Q3H3Ar13G S IVNOSIS TIOHLNOO Sd LINN Sd3 AHL OL YAMOd ONIATddNS AV 138 Sd3 SALVAILOV HOLIMS A3 dN IAYM Sd3 L
13. 3WVAA NO A3 3503 voc g 2018 TWNIWYSL AH3ILVg 10 55 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Lights 1 annoys das H ms oassas L as _ SdlAV1 9 HOLIMS GIONSTOS LYVLS Luvs HOLIMS 145 1 3d3a3g taz 1109 mus HOLIMS AVI GNNOYS SISSVHO di fid 3 VOL 0 _ 1 V0Z zosna INO3 3513 5 Oq3ads JoyejnBay 2D O r AV 133 SISSVHO 133 VOZ yul esn AH3ILVg g 90018 m D Q o TIVNIIAHLL 10 56 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc
14. 9V battery is in good condition If the light flashes the sensor is good Static Timing Light Harness PN 2871745 10 8 Speed Sensor Location 6x6 Models The speed sensor is located on the right front brake caliper mount bracket and can be accessed from the front of the vehicle by turning the steering wheel to the full right Speed Sensor Speed Sensor Testing 6x6 Models Special Tools Required Static Timing Light Harness PN 2871745 Hall Sensor Probe Harness PN 2460761 1 Disconnect wire harness from speed sensor and remove sensor from right front brake caliper mount 2 Connect the wires from the Static Timing Light Harness to the sensor 3 pin connector using the Hall Sensor Probe Harness PN 2460761 3 Pass a screwdriver back and forth in front of the sensor tip 4 Be sure connections are good and 9V battery is in good condition If the light flashes the sensor is good Wht To Pin B Bik To Pin C Static Timing Light Harness PN 2871745 f q df 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL REAR DIFFERENTIAL SOLENOID Differential Solenoid Overview The differential solenoid is located on the right side of the transmission 4x4 or on the rear gear case 6x6 The solenoid actuates an engagement dog which locks and unlocks the rear differential Refer to Chapter 8 4x4 or Chapter 7 6x6 for information on mechanical operati
15. Do not pull on the wiring Test between the 3 sets of outputs AWD 2WD TURF If any of the tests fail replace the switch assembly Move the switch to AWD There should be continuity between switch pins 2 and 3 5 and 6 Move the switch to 2WD There should be no continuity between any pins Move the switch to TURF There should be continuity between switch pins 1 and 2 4 and 5 LOCATED IN DASH 240 AWD SWITCH E 813 46 NOTE Pins 7 and 8 provide power and ground to light the switch lamp 10 5 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Parking Brake Switch The parking brake switch is located within the parking brake lever Follow the parking brake lever under the dash to locate the internally mounted switch Harness Connector Switch Contact Arm The switch remains in the open position when the park brake lever is not applied When the parking brake lever is applied the switch makes contact and sends voltage to the ECU to illuminate BRAKE in the instrument cluster rider information display area see Park Brake Indicator NOTE If the parking brake is applied the ECU will rev limit the engine at 1300 RPM until the parking brake is released This feature has been added to prevent drive away with the parking brake applied If trying to perform an engine diagnostic running test with
16. current ignition cycle causing the MIL to illuminate Diagnostic trouble codes will remain stored in the gauge even if MIL turns off until the key is turned off 1 If the trouble code s are not displayed use the MODE button to toggle until CK ENG displays on the information display area 2 Press and hold the MODE button to enter the diagnostics code menu 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL 3 A set of three numbers will appear in the information area 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 The second number located top right can be 2 to 6 digits in length This number equates to the suspected area of fault SPN The third number located bottom right can be 1 to 2 digits in length This number equates to the fault mode Instrument Cluster Pinouts S JO OO QE OE hDOOOOOOC SS i FUNCTION PIN CAN High 1 gt f EDEN CAN Low 2 L _ Switched Power Vdc 3 _ x _ Constant Power Vdc 4 Ground 5 High Beam Input 8 Fuel Level Sensor 11 SPN Suspect Parameter Number FMI Failure
17. the parking brake applied disconnect the switch harness connector to allow the engine to rev higher than 1300 RPMs 10 6 Testing The Parking Brake Switch 1 Disconnect the harness connector at the parking brake switch Orange Red and Red Yellow wires 2 Place the ohmmeter leads onto the switch terminals The reading should be infinite OL LOCATED ON PARK BRAKE LEVER PARK BRAKE SWITCH SWITCH CONNECTS WHEN 4 BRAKE LEVER PULLED BRAKE SET YES B BRAKE RELEASED NO CAVITY CAVITY LEVER POSITION CONTINUITY A B A 3 Apply the parking brake Continuity should now exist between the switch terminals If no continuity exists when the parking brake is applied try to clean the switch terminals and re test Replace switch if necessary Park Brake Indicator This warning is used to notify the operator that the park brake lever is engaged When the park brake is fully engaged BRAKE appears in the rider information display Engine speed is limited to 1300 RPM in all gears except neutral If throttle is applied this limiting feature prevents operation which protects the park brake pads from excessive wear 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL 2011 Transmission Gear Position Switch 2012 Transmission Gear Position Switch 1 Disconnect the transmission switch harness by lifting 1 Disconnect the trans
18. to bring the level back to the upper level mark on the battery case 6 Charge battery for 3 5 hours at 1 10 of its amp hour rating Examples 1 10 of 9 amp battery 9 amp 1 10 of 14 amp battery 1 4 amp 1 10 of 18 amp battery 1 8 amp recommended charging rates 7 Check during initial charging to see if electrolyte level has fallen and if so fill with acid to the upper level After adding charge for another hour at the same rate NOTE This is the last time that electrolyte should be added If the level becomes low after this point add only distilled water 8 When charging is complete install the filling plugs firmly IMPORTANT Do not apply excessive pressure Finger tighten only Do not over tighten 9 Wash off spilled acid with water and baking soda solution paying particular attention that any acid is washed off the terminals Dry the battery case Battery Inspection The battery is located under the hood 1 Inspect the battery case for obvious damage such as cracks or leaks Look for discoloration warping or raised top which may indicate the battery has overheated or been overcharged 10 32 2 Make sure the battery top is clean and dry A dirty battery actually discharges across the grime on top of the case Use a soft brush and a baking soda solution Make sure plugs are finger tight so cleaning solution doesn t get into the cells and neutralize the acid 3 Inspect the battery terminal
19. traveled by the vehicle on each trip To reset the trip meter 1 Toggle the MODE button to TRIP 1 2 To reset to 0 push and hold the MODE button until the distance display changes to 0 Tachometer RPM Engine RPM can be displayed digitally Engine Temperature Engine temperature can be displayed in F or C Refer to Units of Measurement to change the format 10 12 Engine Hours Engine hours are logged anytime the engine is running Total hours can not be reset Programmed Service Interval The initial factory service interval setting is 50 hours Each time the engine is started the engine hours are subtracted from the service interval hours When the service interval reaches 0 the LCD wrench icon will flash for approximately 10 seconds each time the engine is started To change the hour setting or reset the function follow these steps 1 Toggle the MODE button until the wrench icon is displayed in the information area 2 Press and hold the MODE button until the information display area begins to flash 3 Toggle the MODE button to increase the service interval hours in 5 hour increments to a maximum of 100 hours 4 To turn off the service interval function toggle the MODE button until OFF is displayed 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc EL
20. wiring and establish a connection Wrench ignition power to the ECM instructions es Yes Y Y Replace Power Steering Module if any of the Error Codes are present from Table 1 Replace EPS Perform further testing if Error Codes are present from table 2 Table 1 Error Codes requiring Power Steering Replacement Table 2 Error Codes Requiring Additional Troubleshooting 1 Position Encoder Error 2 EPS Software Error 3 Steering Torque Sensor Full Failure 4 Steering Excessive Current Error 5 Steering Over Current Shutdown 1 EPS Inverter Temperature check for mud debris on EPS 2 Battery Voltage Over Under check bike s charging system and battery 3 Calibration Error Relfash EPS Unit These Error Codes must have multiple occurrences or you must be able to duplicate the condition before replacing the EPS unit EPS Inverter Temperature Test Battery Voltage Over Under Test 1 Verify that Power Steering module heat sink surface top surface is clean and free of mud and dirt Make a note of how much debris was 1 Disconnect 2 pin Power Connector to EPS and verify battery voltage 12 14 VDC is present on on heat sink before cleaning Record all power steering error codes and then clear all error codes EPS inverter temperature can be monitored through Digital Wrench 2 Allow vehicle to set and cool for at least 2 hours 3 Drive vehicle for 30 minutes of left and right
21. 31OS 1 3109 5 JAHA 3503 voc osns AV 133 SISSVHO asna g X90718 TIVNIIWH3 L AH3ILVH 10 53 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Vehicle Speed Sensor 1 51 YALAWOGSAdS AHL OL MHOMLAN NO L SZ 5 7 gez WO3 OQ33dS daN IAYM 1soNovia HY loo Sd3 di Nd 1303 3SVSS3IN Q33dS SLIWSNVMH L Nid NO W93 SH31N3 TVN9SIS SSA HOSN3S Q33dS 319IH3A m D Q o r INO3 3Sf4 g 42018 TWNIAWYSL AH3ILVS 10 54 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL ECM Wake Up Fuel Pump and Level Ignition Coil YMd INO3 30Mds esz 9 Wo3 Old 1109 j S In zonas AV 133 MOO _ 992 Woa SSZ 612 NO 202 103 738 133 dfir3xvM 602 WO3 301195 9 5 4 HOLIMS 353 4 VOL NO Pia SHOSN3S 3NION3 oq3ads NO 5102 OL 5 S3dlAOMd W23 1303 OL 39V L1OA AH3L1V8 ONILINSSY NOD 1905 ANY NOWIAOO 1109 OL OSNIGIAOSHd AV 133 1338 OL LAdLNO NI SLINSSAY IN23 OL IVNOIS df1
22. Dielectric Grease PN 2871329 4 Connect battery cables A WARNING To avoid the possibility of explosion connect positive cable first and negative cable last 5 After connecting the battery cables install the cover on the battery and attach the hold down strap 6 Install clear battery vent tube from vehicle to battery vent WARNING Vent tube must be free from obstructions and kinks and securely installed If not battery gases could accumulate and cause an explosion Vent should be routed away from frame and body to prevent contact with electrolyte Avoid skin contact with electrolyte as severe burns could result If electrolyte contacts the vehicle frame corrosion will occur 7 Route cables so they are tucked away in front and behind battery Off Season Storage See Chapter 2 procedures Maintenance for battery service 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL STARTER SYSTEM Troubleshooting Starter Motor Does Not Run Battery discharged Low specific gravity Loose or faulty battery cables or corroded connections see Voltage Drop Tests Related wiring loose disconnected or corroded Poor ground connections at battery cable starter motor or starter solenoid see Voltage Drop Tests Faulty key switch Faulty starter solenoid or starter motor Engine problem seized or binding can engine be rotated ea
23. ECTRICAL Units of Measurement Standard Display Metric Display Distance Miles MPH Kilometers KM H d 1 71 Time 12 Hour Clock 24 Hour Clock V 7 Temperature Fahrenheit Celsius To change between Standard and Metric units c4 HL I measurement follow these steps 1 Turn the key to the OFF position 2 Pressandhold the MODE button while turning the key The clock displays the time in a 12 hour or 24 hour format to the ON position Refer to Units of Measurement to change the format Standard 12 hour Metric 24 hour set the clock When the display flashes the distance setting tap the follow these steps MODE button to advance to the desired setting 1 Toggle the MODE button until the odometer is displayed 2 Press and hold the MODE button until the hour TE segment flashes Release the button 1 3 With the segment flashing tap the MODE button to La x _ advance to the desired setting 5 1t L 4 Press and hold the MODE button until the next r segment flashes Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the 7 clock mode 4 Press and hold the MODE button to save the setting and advance to the next display option 5 Repeat the procedu
24. ELECTRICAL CHAPTER 10 ELECTRICAL GENERAL INFORMATION secs RR Re Wada ee Soe sews ba RR ERES 10 3 SPECIAL TOOLS ELECTRICAL SERVICE NOTES 10 3 COMPONENTS UNDER HOOD BEHIND DASH PANEL 10 3 SWITCHES CONTROLS occas Sarai qi bate e eatob ter mE xd Pads qus 10 4 BRAKE LIGHT 5 10 4 HEADLAMP 5 10 4 IGNITION KEY SWITCH eee 10 5 AWD 2WD TURF SWITCH wayua e 10 5 PARKING BRAKE 2 10 6 2011 2012 TRANSMISSION GEAR POSITION SWITCH 10 7 VEHICLE SPEED SENSOR Pes RR wad ERROR REX 10 8 SPEED SENSOR LOCATION TESTING 4X4 5 10 8 SPEED SENSOR LOCATION TESTING 6X6 MODELS 10 8 REAR DIEFERENTIAL SOLENOID d Sce see 10 9 DIFFERENTIAL SOLENOID OVERVIEW CIRCUIT OPERATION 10 9 INSTRUMENT GLUS TER etis oon ee e ERI ERE MEUS q UE Soe Mon eta 10 10 RIDER INFORMATION DISPLAY e 10 11 INFORMATION DISPLAY AREA 10 11 DIAGNOSTIC MODE ee eU e EL 10 14 INSTRUMENT CLUSTER PINOUTS 2 10 15 INSTRUMENT CLUSTER REMOVAL INSTALLATION 10 16 AVL WHEBLIDRIVE COILS erste ome sso eL Ead 10 17 HEADLIGHTS 5 06 0 ard r m 10 17 HEADLI
25. GHT ADJUSTMENT 10 17 HEADLIGHT BULB 0 10 18 HEADLIGHT HOUSING REMOVAL 10 18 HEADLIGHT HOUSING INSTALLATION 10 19 TAILLIGHT BRAKE EIGHT xui SV Ree eh amsaq ERE 10 20 LED LAMP REPLACEMENT 10 20 COOLING SYSTEM v ci ERE gua Gwe Pate aes QU ER aa Dan ges 10 21 COOLING SYSTEM BREAK OUT DIAGRAM 10 21 FAN CONTROL CIRCUIT OPERATION TESTING BYPASS TEST 10 22 COOLANT TEMPERATURE SENSOR 10 22 EFLDIAGNOSTIGS io DERE Are T a tigated cena E e Dc baw qua qupa su banda dts 10 22 FOUEL SENDER u aaa ata Satna au OR etian tatc desean No ie b Suasana RR 10 22 FUSE BOX FUSES RELAYS CIRCUIT BREAKER 10 23 OVERVIEW OPERATION MODEL YEAR 2011 10 23 OVERVIEW OPERATION MODEL YEAR 2012 10 24 FUSE BOX DETAIL niei er bx a ma Ck eT PDA 10 25 RELAY OPERATION 2 10 26 CHANGING SYSTEM iisas eather poe ede adi ate 10 28 CURRENT DRAW KEY OFF 2 10 28 CHARGING SYSTEM BREAK EVEN TEST 10 28 CHARGING SYSTEM ALTERNATOR 5 10 28 REGULATOR RECTIFIER 2 lu usan eee eee de
26. GHTS p cu TET 10 56 10 2 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL GENERAL INFORMATION Components Under Hood Special Tools The following components can be accessed under the hood Part Number Tool Description Voltage Regulator in front of radiator PV 43568 Fluke 77 Digital Multimeter PV 43526 Connector Test Kit 2870630 Timing Light PU 50338 Battery Hydrometer 2460761 Hall Sensor Probe Harness 2871745 Static Timing Light Harness PU 47063 Digital Wrench Diagnostic Software PU 47471 Digital Wrench SmartLink Module Kit Battery Battery Cables Terminal Block Starter Solenoid Relays Fuses Digital Wrench Diagnostic Connector Components Behind Dash Panel SPX Corp 1 800 328 6657 or http polaris spx com The following components can be accessed with the dash E anel removed see Chapter 5 for removal Electrical Service Notes P 7 Keep the following notes in mind when diagnosing an DSIRE ne Cluster electrical problem AWD 2WD TURF Switch e Refer to wiring diagram for stator and electrical Headlight Switch component resistance specifications 12 VDC Accessory Power Points When measuring resistance of a component that Ignition Switch has a resistance value under 10 Ohms remember I to subtract meter lead resistance from the reading Parking Brake Switch
27. GREEN 8 Pin FUNCTION Main Power 30A Protected Ground Key On Battery Voltage CAN High Signal CAN Low Signal Proper EPS System Diagnosing READ BEFORE YOU REPLACE THE EPS UNIT IMPORTANT Try to reflash the EPS unit before attempting to replace it A simple reflash may be all that is needed to repair the EPS problem Always reflash the EPS unit as the first step in diagnosing an EPS problem 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL EPS System Breakout Model Year 2011 TERMINAL BLOCK ACC GND B rod rN ry u AN _ rN N 1 VV N VJ WU nav _ CAN Y CAN GN ISE OCK KEY ON USE BLOCK yf z B N T e 0G RELAY COIL B RELAY POWER IN re RELAY COIL B D4 EPS FUSE OUT 5 RELAY PWR OUT USE IN Mui LOCATED UNDER HOOD e KEY ON B Z o 843 EPS POWER EPS SIGNAL POWER STEERING EPS POWER A PIN FUNCTION A BATTERY B BATTERY EPS SENSOR B PIN FUNCTION IGNITION SIGNAL 4 CAN BUS LOW 8 CAN BUS HIGH 10 43 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL EPS Syst
28. LECTRICAL NOTE Note the alignment marks on both ends of the starter motor casing These marks must align during reassembly 3 Remove the front bracket assembly and the rear bracket assembly Remove the shims from the armature shaft and inspect the O rings located on the armature housing Shims _ an NOTE The reassembly shims will be replaced during Brush Inspection Replacement 1 Measure resistance between starter input terminal and insulated brushes The reading should be 3 ohms or less Remember to subtract meter lead resistance 10 36 2 Measure resistance between insulated brush and starter housing Reading should be infinite OL Inspect insulation on brush wires for damage and repair or replace as necessary 3 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate Slide brush end frame off end of starter NOTE The electrical input post must stay with the field coil housing 4 Measure resistance between ground brush and brush plate Resistance should be 3 ohms or less Brush Inspection 1 Measure length of each carbon brush Replace brush assembly when worn to 5 16 8 mm or less The brushes must slide freely in their holders Brush Length ze Limit 5 16 8 mm lt 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Brush Replacement 1 Remove terminal
29. LOCATED UNDER CARGO BOX ON FRAME ELECTRICAL INSTRUMENT CLUSTER Overview The instrument cluster displays critical vehicle information to the user Reference the following page for display functions and descriptions MODE Button TU ZT NOTE Some features are not applicable to all models IMPORTANT The use of a high pressure washer may damage the instrument cluster Wash the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the instrument cluster lens Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster 10 10 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Rider Information Display The rider information display is located in the instrument cluster All segments will light up for 1 second at start up NOTE If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer 1 Vehicle Speed Display Analog display of vehicle speed in MPH or km h 2 Information Display Area Odometer Trip Meter Tachometer Engine Temperature Engine Hours Service Info Clock LCD display of the service hour interval total vehicle mil
30. LOZ 1294 9poIN Sd3 Asn voe Asn voe rr ev TA ee 602 INO3 HOSN3S INO3 3503 qaads GSHOLIMSNN 3505 voz 3TOIH3A 5 HOLIMS NO ES g 1 2018 05 qana AaaLtvag 10 51 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Engine Start Starter Interlock SdINV1 3 Vv48 SS3NHVH XO HOLIMS 3 vug SdNV1 11 HOLIMS GION310S ANNONO 1MVIS 1MVIS GION31OS LYVLS OL 5 NOILISOd LYVLS OL A35 NHOLO3NNOO 3d338 99V ldS 8 SLH91 GQNNOYSD L SZWO3 qQION31OS LYVLS OL 9 OL HSNd SLHSM 3503 voc 5 AW144u SISSVHO g L M20 18 TWNIWYSL AYSLLIVE 10 52 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL AWD TURF N3dO VILN32324IG JHL 990 INN OL Q3Q33N LNAYYND S3GIAOSHd AV T3 31V1S 38f L Q3 LLIWS3d SI 35381 N3HM 212 Nid LV LAdLNO SLSANODSAY LLZ Nid WO3 LV ANNOYS sunt siz noa Hf ezzwo3 J aNnouo Q3LLINYAd SI N3HM SNOLLIQNOO 212 Nid LV LNdLNO SLSANODAY 822 Nid W94 LY GION
31. Mode Identifier 4 Use the trouble code reference table in the EFI Chapter for a description of each code 5 f more than one code exists press the MODE button to advance to the next trouble code 6 To exit the diagnostic mode press and hold the MODE button or turn the ignition key OFF once the codes are recorded 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 10 15 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Instrument Cluster Removal NOTE Do not allow alcohol or petroleum products to come in contact with the instrument cluster lens 1 Remove dash panel from the dash see Chapter 5 2 Disconnect the wire harness connector from the back side of the instrument cluster 3 Push the instrument cluster out from the back side of the dash panel while securely holding the panel and rubber mount Dash Panel Instrument Cluster NOTE Do not remove the rubber mount from the dash panel Only remove the rubber mount if necessary 10 16 Instrument Cluster Installation 1 3 Spray a soap and water mixture onto the outer surface area of the instrument cluster This will help the instrument cluster slide into the rubber mount more easily Be sure the rubber mount inside the dash panel is fully installed and that the indexing key on th
32. _ TERMINAL BLOCK ACC GND B Y RD DB M TOP VIEW COVER REMOVED RD 20 AMP CIRCUIT BREAKER RELAY FUSE BLOCK all 10 21 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Fan Control Circuit Operation Testing Power is supplied to the fan via the Orange Black wire when the relay is ON The ground path for the fan motor is through the Brown harness wire Refer to RELAYS later in this chapter for more information on fan functions AX CAUTION Keep hands away from fan blades during operation Serious personal injury could result NOTE The fan may not function or operation may be delayed if coolant level is low or if air is trapped in the cooling system Be sure cooling system is full and purged of air Refer to Chapter 2 Maintenance for cooling system information Fan Control Circuit Bypass Test 1 Disconnect harness from coolant temperature sensor on the engine cylinder head see Chapter 4 for location 2 Start the engine After a few seconds the fan should start running and the Check Engine indicator should display on the instrument cluster This indicates all other components are working properly 3 If the fan does not run or runs slowly check the fan motor wiring ground motor condition circuit breaker and mechanical relay
33. an ade 10 29 CHARGING SYSTEM TESTING FLOW CHART 10 30 10 1 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL BACHE SERVICE Lors ene cit OR Sat au sh E eo ae a BATTERY TERMINALS BOLTS TERMINAL BLOCK 10 31 BATTERY ACTIVATION hana ral gee eae oe ee ee uqta 10 31 BATTERY INSPECTION REMOVAL INSTALLATION 10 32 CONVENTIONAL BATTERY TESTING 10 33 OCV OPEN CIRCUIT VOLTAGE 10 33 SPECIFIC GRAVITY TEST ss sce em bese Rv erem a eee RT 10 33 LOAD TEST cL sce ede rp E eade Suite lc ep eek gue etc algal aed ae 10 34 BATTERY CONDUCTANCE ANALYZER 10 34 CHARGING PROCEDURE 00 00 0020 ne 10 34 OFF SEASON STORAGE ssssesessese eee 10 34 STARTER SYSTEM ia vio otk tet or de OS betae OG ORO T ae TROUBLESHOOTING 10 35 VOLTAGE DROP TEST cca sa aaa ib Sande kode Mea ate 10 35 STARTER MOTOR REMOVAL DISASSEMBLY 10 35 BRUSH INSPECTION REPLACEMENT 10 36 ARMATURE TESTING 0 0 000002 s 10 37 STARTER REASSEMBLY INSTALLATION 10 37 STARTER DRIVE ont er
34. ater than 0 5 ohms clean the switch contacts and re test Replace switch if necessary 10 4 Headlamp Switch 1 Disconnect the headlamp switch harness by depressing the connector locks and pulling on the connector Do not pull on the wiring Test between the 3 sets of outputs HIGH LOW OFF If any of the tests fail replace headlamp switch assembly Move the switch to HIGH There should be continuity between switch pins 2 and 3 5 and 6 Move the switch to LOW There should be continuity between switch pins 2 and 3 4 and 5 Move the switch to OFF There should be continuity between switch pins 1 and 2 NOTE Pins 7 and 8 provide power and ground to light the switch lamp 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc Ignition Key Switch 1 Disconnect the key switch harness by lifting the connector lock and pulling on the connector Do not pull on the wiring Test between the 3 sets of outputs OFF ON START If any of the tests fail replace ignition switch assembly Turn the ignition key to ON There should be continuity between switch pins C and D Turn the ignition key to START There should be continuity between switch pins A and B C and D LOCATED IN DASH ELECTRICAL AWD 2WD TURF Switch 1 Disconnect the AWD 2WD TURF switch harness by depressing the connector locks and pulling on the connector
35. cator LED icon illuminates when gear selector is in the neutral N position 13 Gear Position Indicator Displays gear selector position H High L Low N Neutral R Reverse Gear Signal Error shifter stuck between gears 14 Power Steering System MIL LED icon illuminates when a fault has occurred with the power steering system This indicator illuminates when the key is turned to the ON position and goes off when the engine is started 15 Turn Signal Hazard Lamp Indicator LED icon illuminates whenever the LH RH or hazard lamps are activated International Models Only 16 Helmet Seat Belt Indicator LED icon illuminates for several seconds when the key is turned to the ON position The lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating the vehicle Information Display Area The LCD portion of the instrument cluster is the information display area Information displayed in this area includes odometer trip meter engine RPM engine hours service interval clock engine Diagnostic Trouble Codes DTCs and power steering DTCs Odometer The odometer records and displays the total distance traveled by the vehicle The odometer can not be reset 10 11 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Trip Meter The trip meter records the miles
36. cts as a pilot hole to properly align the starter drive bendix with the flywheel This helps to prevent binding and starter damage Starter Drive If the garter spring is damaged the overrun clutch may fail to return properly Use either of the following methods to remove and install a new garter spring WE B Z 5 2 A Gear Assembly E C B Thrust Washer C Busing D Retaining Ring E Thrust Washer F Stopper G Cover H Spring 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL 1 Screw the overrun clutch out to the engaged position on the pinion shaft assembly Use a small piece of wire with the end bent in a hook and pick the old spring out of its channel Slide it off the end of the shaft Slide the new spring over the overrun clutch and into the spring groove Make sure that the spring is positioned between the shoe alignment pins and the back flange of the anti kick out shoes 2 Remove the retaining ring thrust washer spring retainers and clutch return spring Screw the overrun clutch off the end of the pinion shaft Remove the old spring and install a new one Lightly grease the pinion shaft and reinstall the clutch spring retainers end washer and lock ring in the reverse order Make sure the end washer is positioned properly so that it will hold the lock ring in its groove Starter Solenoid Bench Test Test the start solenoid by powe
37. e rubber mount is lined up with the keyway in the dash panel Hold the dash panel securely and insert the instrument cluster into the dash panel Twist the instrument cluster gently in a clockwise motion to properly seat the instrument cluster Apply pressure on the bezel while pressing down on the instrument cluster 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL ALL WHEEL DRIVE COILS Operation Overview When the AWD switch is ON 12 VDC power is present at the hub coil If the criteria is met the Engine Controller provides a ground path brown white wire When this occurs the AWD icon should display in the instrument cluster The AWD system must be grounded to operate Diagnosing System Failures Verify the AWD switch is functional and that a minimum of 11 volts is present at the hub coil Verify the AWD hub coil is functional Test the AWD hub coil using an ohm meter See specifications below 11 VOLTS MINIMUM REQUIRED TO POWER HUB COIL HUB COIL Test Resistance Readings should be GY to BN WH 24 Ohms GY to Ground No Connection AWD Hub Coil Resistance 24 596 Verify the wiring harness wiring connectors connector pins and grounds are undamaged clean and connected properly Verify continuity of wire connections with a volt ohm meter IMPORTANT Verify all wires and w
38. e to twist the O rings upon installation as shown below Reinstall the bulb into the housing and rotate it clockwise 90 to lock it in place Reinstall the front fascia and securely tighten all fasteners Install all T27 Torx head fasteners shown Adjust headlights using the Headlight Adjustment procedure 10 19 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL TAIL LIGHT BRAKE LIGHT LED Lamp Replacement 1 From the rear of the LED lamp remove the 2 T20 Torx head screws retaining the lamp assembly T20 Screws IS 2 Remove the lamp from the cargo box and disconnect the tail light brake light wire harness NOTE Before replacing the LED lamp assembly use a digital multi meter to test the harness to ensure the lamp is receiving 12 volts and that a ground path is present 3 Ifthe LED still does not work replace the LED lamp assembly with the recommended lamp 4 Reinstall the assembly by reversing this procedure 5 Test the tail light brake light after installation to verify proper function 10 20 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL COOLING SYSTEM Cooling System Break Out Diagram DG r VI WH I ii I Lo c ni 66009037 H 0000 580000 COOLANT TEMP SENSOR OG WH
39. ear Diff Solenoid Relay is mounted separately attached to the frame under the rear cargo box 10 27 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL CHARGING SYSTEM Current Draw Key Off AX CAUTION Do not connect or disconnect the battery cable or ammeter with the engine running Damage will occur to electrical components Connect an ammeter in series with the negative battery cable Check for current draw with the key off If the draw is excessive loads should be disconnected from the system one by one until the draw is eliminated Check component wiring as well as the component for partial shorts to ground to eliminate the draw Current Draw Inspection Key Off Current Draw Key Off Maximum of 01 DCA 10 mA Charging System Break Even Test CAUTION Do not allow the battery cables to become disconnected with the engine running Follow the steps below as outlined to reduce the chance of damage to electrical components The break even point of the charging system is the point at which the alternator overcomes all system loads lights etc and begins to charge the battery Depending on battery condition and system load the break even point may vary slightly The battery should be fully charged before performing this test 10 28 A WARNING Never start the engine with an ammeter connected in series Da
40. easure the voltage across each leg of the stator by connecting the meter leads to the wires leading from the alternator Y1 to Y2 Y1 to Y3 Y2 to 4 Refer to the following table for approximate Voltage readings according to RPM Test each leg at the specified RPM in the table Example The alternator current output reading should be approximately 18 VAC at 1300 RPM between each leg The Regulator Rectifier is located in front of the radiator accessed by removing the upper fascia screen Regulator Rectifier NOTE If the regulator rectifier overheats the unit will turn itself off to cool down The unit will turn on again after it has cooled down If it turns off verify the cooling fins are clean free from debris and that adequate airflow is present 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Charging System Testing Flow Chart Whenever charging system problems are suspected proceed with the following system check after verifying that all wires are in good condition connected and not exposed or pinched Using a multitester set on D C volts mea Remove the battery and properly ser sure the battery open circuit voltage test No vice Reinstall the fully charged battery with lights and accessories off It should be or a fully charged shop battery 12 4 volts or more Is it
41. em Breakout Model Year 2012 Ti i EPS RELAY V 3 s JU C21 R 72345 e T iD I DIAGNOSTIC r 59 8 AN YE tl 2 T J o CA bid lt gt f AN 51 CAN unas WE I r amp 4 1 1 D6 1 1 m G6 4 on P 000 Sant AAA B teo Ss 10 44 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL EPS Troubleshooting Power Steering Non Functional with MIL ON Power Steering Non Functional MIL is ON x d b Determine cause ls Battery Voltage lt gt A gt 11 and lt 16VDC gt No gt of incorrect battery W P voltage and repair gt Yes Y Is EPS Fuse OK D No p Replace EPS Fuse P Yes a p d i 12VDC and GND across the gt N No Check EPS Power 2 Pin EPS Connector _ Relay and Circuit with Key On N N p Ww Yes Z i gt d N Check wiring from 2 12 on Pin 3 NS Connector to lt of the 8 pin EPS gt No p Ignition switch Connector Check Ignition SE Pp Switch Circuit gt gt b Yes Y Begin Digital Wrench EPS Troubleshooting Procedure 10 45 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL EPS Troubleshooting Power Steering Non Fu
42. es or km total engine hours a trip meter engine RPM and engine temperature 3 MPH KM H Display MPH is displayed when the instrument cluster is in the Standard mode KM H is displayed when the instrument cluster is in the Metric mode 4 High Beam Indicator LED icon illuminates whenever the Headlamp switch is in the high beam position 5 Fuel Level Indicator LCD bar graph indicating current fuel level All segments will flash when the last segment is cleared indicating a low fuel warning 6 Clock Displays current time in either 12 hour or 24 hour formats 7 Engine Temperature Indicator LED icon illuminates when the ECM determines the engine is overheating The indicators will initially flash to indicate the engine is overheating The indicators will stay lit and not flash if a severe overheating condition exists 8 Service Interval Indicator Preset at the factory and adjustable by the user a flashing wrench symbol alerts the operator that the preset service interval has been reached and maintenance should be performed The wrench icon will flash for 10 seconds upon start up once it reaches 0 9 Check Engine MIL Illuminated when the ECM has detected a Diagnostic Trouble Code in the engine management system 10 AWD Indicator Illuminated when the AWD TURF switch is in the AWD position 11 TURF Indicator Illuminated when the AWD TURF switch is in the TUHF position 12 Neutral Gear Indi
43. for proper operation Repair or replace as necessary If the fan runs with the sensor harness disconnected but will not turn on when the engine is hot check the coolant temperature sensor and connector terminals Coolant Temperature Sensor The coolant temperature sensor can be tested using an ohmmeter or voltmeter 1 With the engine and temperature sensor at room temperature 68 F 20 C disconnect the harness 2 With the meter in the ohms mode place the meter leads onto the sensor contacts 3 Use the table Temperature Resistance table to determine if the sensor needs to be replaced TEMPERATURE F RESISTANCE 68 F 20 C 2 5 k Q 6 212 F 100 186 2 NOTE If the coolant temperature sensor or circuit malfunctions the radiator fan will default to ON 10 22 EFI DIAGNOSTICS EFI Component Testing All EFI component information and diagnostic testing procedures are located in Chapter 4 Refer to Chapter 4 Electronic Fuel Injection System EFI when diagnosing an EFI System FUEL SENDER Testing 1 Drain the fuel tank and remove it from the vehicle see Chapter 4 2 Setfuel tank on a flat surface Using an Ohm meter measure the resistance of the fuel sender 6410 Test Here 3 Allow the sender float to sit in the empty position and compare to specification 4 Slowly tilt the tank so that gravity moves the sender float to the full position and c
44. iring connections have been tested properly with a known good volt ohm meter before suspecting a component failure 8096 of all electrical issues are caused by bad failed connections and grounds HEADLIGHTS Headlight Adjustment The RANGER headlights are adjustable 1 Placethe vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall y 8 in 20 cm 2 Measure the distance from the floor to the center of the headlight X and make a mark on the wall at the same height 2 3 With the vehicle in Neutral and parking brake applied start the engine and turn the headlight switch on 4 The most intense part of the headlight beam should be aimed 8 in 20 cm below the mark placed on the wall in Step 2 NOTE Rider weight must be included in the seat while performing this procedure 5 Locate the T25 Torx head adjustment screw through the wheel well see illustration Adjust the beam to the desired position by loosening the adjustment screw and moving the lamp to the appropriate height Access adjustment through the wheel well 10 17 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL 6 Once the beam is set to the position tighten the adjustment screw Repeat the procedure to adjust the other headlight A WARNING Due to the nature of light utility vehicles and where they are operated headlight lenses become dirty F
45. ld be less than 1 V D C Connect the black tester lead to solenoid end of battery to solenoid cable Connect red tester lead No to solenoid end of solenoid to starter cable Turn Y the ignition key to the start position Reading should be less than 1 V D C Clean the battery to solenoid cable ends or replace the cable Replace the starter solenoid Yes Connect the black tester lead to the solenoid end of the solenoid to starter cable Connect the red tester lead to the starter end of the same cable Turn the ignition key to the start position The reading should be less than 1 V D C Clean the solenoid to starter cable ends or m replace the cable If all of these indicate a good condition yet the starter still fails to turn the starter must be removed for static testing and inspection 10 41 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL ELECTRONIC POWER STEERING EPS EPS Operation The EPS module is an intelligent electronic power steering system that operates off of the vehicle s 12V electrical system It calculates steering assist by sensing the difference between the input torque of the steering post and the output torque required to turn the wheels and then provides assist by energizing an electric motor The process provides a smooth seamless assi
46. mage to the meter or meter fuse will result Do not run test for extended period of time Do not run test with high amperage accessories 1 Using an inductive amperage metering device set to DC amps connect to the negative battery cable 2 With engine off and the key switch and lights in the ON position the ammeter should read negative amps battery discharge Reverse meter lead if a positive reading is indicated 3 Shift transmission into neutral with the parking brake applied and start the engine With the engine running at idle observe meter readings 4 Increase engine RPM while observing ammeter and tachometer 5 Note RPM at which the battery starts to charge ammeter indication is positive 6 With lights and other electrical loads off the break even point should occur at approximately 1500 RPM or lower 7 Withthe engine running turn the lights on and engage parking brake to keep brake light on 8 Repeat test observing ammeter and tachometer With lights on charging should occur at or below 2000 RPM Charging System Alternator Tests Three tests can be performed using a multi meter to determine the condition of the stator alternator Perform tests at Stator Regulator connector STATOR 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL TEST 1 Resistance Value of Each Stator Leg
47. mission switch harness by lifting the connector lock and pulling on the 6 pin connector the connector lock and pulling on the 2 pin connector Do not pull on the wiring Do not pull on the wiring 2 Test transmission switch for continuity in each gear 2 Test transmission switch for continuity in each gear position and compare to the specification table below position and compare to the specifications below RESISTOR MODULE CONTINUITY OUTPUT ECM TRANSMISSION SWITCH REVERSE NEUTRAL INPUT FROM ECM TRANSMISSION SWITCH CONTINUITY FROM TO CAVITY CAVITY GEAR C F PARK REVERSE NEUTRAL LOW HIGH 10 7 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL VEHICLE SPEED SENSOR Speed Sensor Location 4x4 Models The speed sensor is located in the transmission case and can be accessed through the rear RH wheel well area Speed Sensor Testing 4x4 Models Special Tools Required Static Timing Light Harness PN 2871745 Hall Sensor Probe Harness PN 2460761 1 Disconnect wire harness from speed sensor and remove sensor from the transmission 2 Connect the wires from the Static Timing Light Harness to the sensor 3 pin connector using the Hall Sensor Probe Harness PN 2460761 3 Pass a screwdriver back and forth in front of the sensor tip 4 Be sure connections are good and
48. nctional with MIL OFF Power Steering Non Functional MIL is OFF gt Is Battery Voltage gt 11 lt 16VDC 42VDC and GND across the 2 Pin EPS Connector with Key On Yes 12VDC on Pin 3 of the 8 pin EPS Connector Yes Don EPS MIL turns on Wrench EPS 4 during Instrument Cluster Troubleshooting Power Up Self Test Procedure Yes 10 46 No p Determine cause of incorrect battery No voltage and repair No Replace EPS Fuse Check EPS Power No Relay and Circuit Check wiring from Connector to No Ignition switch Check Ignition Switch Circuit MIL Lamp should come on briefly during Instrument Cluster Power Up Is Instrument Cluster EPS MIL lamp OK d Troubleshoot per No p Non Functional and MIL ON 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL EPS Troubleshooting Using Digital Wrench Troubleshooting Procedure Advises Digital Wrench Y Connect Digital Wrench to Diagnostic Connector Turn key to On Position Check wire harness for damaged shorted CAN bus wires Repair or replace harness if necessary Is Digital Wrench able to establish a connection to EPS No gt Yes Y Trace Repair CAN bus Is DW able to Follow Digital
49. nut with lock washer flat washer large phenolic washer the small phenolic spacers and sealing O ring Inspect O ring and replace if damaged 2 Slide positive brush springs to the side pull brushes out of their guides and remove brush plate CAUTION Some cleaning solvents may damage the insulation in the starter Care should be exercised when selecting an appropriate solvent If the commutator needs cleaning use only electrical contact cleaner Armature Testing 1 Remove armature from starter casing Note order of shims on drive end for reassembly Inspect surface of commutator Replace if excessively worn or damaged Using a digital multitester measure the resistance between each of the commutator segments The reading should be 3 ohms or less 4 Measure the resistance between each commutator segment and the armature shaft The reading should be infinite no continuity Bars Check commutator bars for discoloration discolored in pairs indicate shorted coils requiring replacement of the starter motor Place armature in a growler Turn growler on and position a hacksaw blade or feeler gauge lengthwise 1 8 3 cm above armature coil laminates Rotate armature 360 If hacksaw blade is drawn to armature on any pole the armature is shorted and must be replaced A CAUTION Use care when handling starter housing Do not drop or strike the housing as magnet damage i
50. ompare to specification 5 Ifthe readings are out of specification erratic or LCD display sticks check the following before replacing the fuel pump assembly Loose float Float contact with tank Bent float rod If none of the conditions exist the fuel sender assembly is faulty Replace the fuel pump assembly see Chapter 4 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL FUSE BOX FUSES RELAYS CIRCUIT BREAKER Overview Operation Model Year 2011 Located in the fuse box under the hood the fuses provide overload protection for wiring and components such as the instrument cluster ECU EFl system main harness lights accessories and power steering The relays assist with component operation like the cooling fan fuel pump EFI system drive system and electronic power steering A separate 20 amp circuit breaker located near the fuse relay box protects the fan motor circuit TERMINAL BLOCK ACC GND Bt j TOP VIEW OF RELAY BATTERY VOLTAGE 12V CIRCUIT BREAKER 20 AMP FAN CIRCUIT FAN CIRCUIT BREAKER IN BREAKER OUT RD E FUS e SPLICE 1 18 e e RELAY FUSE BLOCK BUSS CAVITIES C7 CS C3 BUSS CAVITIES A7 AS BUSS CAVITIES DS D7 DS 06 0G RD BU eX u lt 0G BK x RD DB RD DB RD WH eg BN BN wo 0 0 D6 YE RD GN 2 uim
51. on Differential Solenoid Differential Solenoid Circuit Operation The Rear Diff Solenoid Relay is located on the frame under the rear cargo box When the switch is pushed to activate TURF a ground is provided to the ECU from the AWD 2WD TURF Switch Depending on engine speed gear position criteria and park brake input the ECU energizes the Rear Diff Solenoid Relay allowing it to enable the differential solenoid NOTE The rear differential will not unlock if the parking brake is set If the differential fails to switch from operational modes Check the solenoid and relay connectors Look for loose wires or bad connections Check for power from the relay connector to ensure the solenoid has power to be activated Check the switch wires for loose connections Remove solenoid from rear differential and ensure the solenoid plunger is actuating CAUTION Do not power the solenoid with 12 Volts for more than 1 second or damage may occur to solenoid Ground gt Y REAR DIFFERENTIAL SOLENOID LOCATED ON REAR DIFFERENTIAL NOTE POWERED TO UNLOCK DIFFERENTIAL CAUTION DO NOT POWER 12V FOR MORE THAN 1 SECOND LOCATED IN DASH AWD 2WD TURF SWITCH PIN A SOL RD PIN SOL BU 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc BAT CRD B SIGNAL GN PIN C GND BN TURF SOLENOID DRIVER
52. on harness side of voltage regulator p Check terminal block battery and and battery connections Also check wire connections and wire condition Is voltage present Repair or replace faulty wiring or components Yes If all of the previous tests indicate a good condition but the charging voltage does not rise above battery voltage at the connector or wire harness replace the voltage regulator 10 30 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL BATTERY SERVICE Battery Activation Battery Terminals Bolts A WARNING Use Polaris corrosion resistant Nyogel grease PN 2871329 on battery terminal bolts Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Battery Terminal Block A WARNING The terminal block is located under the hood next to the battery and fuse box The te
53. re to change remaining display settings 10 13 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Under Over Voltage This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and a high electrical load is applied lights cooling fan or other accessories If battery voltage drops below 11 volts a warning screen will display Lo and provide the present battery voltage If voltage drops below 8 5 volts LCD backlighting and icons will turn off If battery voltage rises above 15 volts a warning screen will display OV and provide the present battery voltage If voltage rises above 16 5 volts LCD backlighting and icons will turn off 10 14 Park Brake Indicator This warning is used to notify the operator that the park brake lever is engaged When the park brake is fully engaged BRAKE appears in the rider information display Engine speed is limited to 1300 RPM in all gears except neutral If throttle is applied this limiting feature prevents operation which protects the park brake pads from excessive wear Diagnostic Mode 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
54. requent washing is necessary to maintain lighting quality Riding with poor lighting can result in severe injury or death Headlight Bulb Replacement 1 Open the hood 2 Locate the bulb on the back side of headlight 10 18 4 Unplug the headlight bulb from the wiring harness Be sure to pull on the connector not on the wiring Wire Harness 5 Install the wire harness onto the new headlight bulb 6 Install the bulb into the housing and rotate it clockwise 90 to lock it in place NOTE Make sure the tab on the bulb locates properly in the housing Headlight Housing Removal 1 Open the hood 2 Remove the front facia to access the headlight housing Remove all T27 Torx head fasteners shown 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL 3 Carefully pull the fascia out far enough to access the headlight housing EN Headlight P Housing 4 Remove the bulb from the headlight housing see Headlight Bulb Replacement 5 Remove the O rings A from each side of the headlight housing Remove the adjustment screw B and pull the headlight from the brackets Headlight Housing Installation 1 Install the headlight housing by pressing the headlight tabs back into the brackets Secure the headlight housing with the rubber O rings on each side A Install the adjustment screw B NOTE Be sur
55. ring the solenoid using battery voltage for a maximum of 5 seconds With the solenoid energized resistance should read about 0 0 5W between terminals A and B If resistance measurement is out of specification replace the starter solenoid Energize START SOLENOID Starter Solenoid Operation To energize the Starter Solenoid the following must occur The brake must be applied to provide 12V power via the Orange wire The key switch must be turned to the Start position to provide a ground path via the Green White wire Once the pull in coil is energized the solenoid provides a current path for 12V power to reach the starter motor O GROUND 10 39 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Starter Exploded View Indicates Do not reuse Replace with new parts 10 40 ROI Rubber Ring Brush Spring Thrust Washer Gear Assembly O Ring Brush Complete O Ring Thrust Washer Shaft Complete 10 Gear Assembly 11 Through Bolt 12 Cover 13 Stopper 14 Snap Ring 15 Washer 16 Flange Bolt 17 Thrust Washer 18 Flange Bushing 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL STARTING SYSTEM TESTING FLOW CHART Condition Starter fails to turn over the engine With the
56. rminal block provides easy hookup for accessories The gases given off by a battery are explosive Any spark or open flame near a battery can cause an explosion which will spray battery acid emin n on anyone close to it Should there be contact ermina with battery acid wash the affected area with Blok as large quantities of cool water and seek immediate medical attention To ensure maximum service life and performance from a new battery perform the following steps NOTE Do not service the battery unless it will be put into regular service within 30 days After initial service add only distilled water to the battery Never add electrolyte after a battery has been in service NOTE New Battery Battery must be fully charged before use or battery life will be significantly reduced 10 30 of the battery s full potential T To activate a new battery Terminal Block Nuts 1 Remove all the filling plugs 20 25 in Ibs 2 3 2 8 Nm 2 Remove the sealing tube red cap from vent fitting 3 Place battery on a level surface Fill battery with electrolyte to upper level marks on the battery case 10 31 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL NOTE Never activate a battery on the vehicle Electrolyte spillage can cause damage 4 Set battery aside to allow for acid absorption and stabilization for 30 minutes 5 Add electrolyte
57. s screws and cables for breakage corrosion or loose connections Clean the terminals and cable ends with a wire brush and coat terminals with Nyogel 4 Check the electrolyte level and add distilled water if necessary UPPER LEVEL LOWER LEVEL POLARIS eN Pb Pb nn BATTERY IC READING PA 19612 MADE IN U S A IMPORTANT Don t add acid use distilled water only 5 Check the vent tube Make sure it s not kinked pinched or otherwise obstructed Battery Removal Installation See Chapter 2 Maintenance for procedures battery service 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL Conventional Battery Testing Whenever a service complaint is related to either the starting or charging systems the battery should be checked first Following are three tests which can easily be made on a battery to determine its condition OCV Test Specific Gravity Test and Load Test OCV Open Circuit Voltage Test Battery voltage should be checked with a digital multimeter Readings of 12 6 volts or less require further battery testing and charging See the following chart NOTE Lead acid batteries should be kept at or near a full charge as possible Electrolyte level should be kept between the low and full marks If the battery is stored or used in a partially charged condition or with low electrolyte levels hard crystal sulfation will
58. s possible If magnets are damaged starter must be replaced Starter Reassembly Installation 1 Install brush plate to field magnet housing aligning index tab 10 37 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc ELECTRICAL 2 Install O ring two small phenolic spacers large phenolic washer flat washer lock washer and terminal nut 3 While holding brush springs away from brushes push brushes back and hold in place 4 Slide armature into field magnet housing Release brushes 5 Lightly grease the drive roller bearing and reinstall drive end frame on armature Inspect seal for wear or damage Replace drive end cap if necessary Roller Bearing 6 Be sure wire insulation is in place around positive brush wire and pushed completely into slot on phenolic plate 7 Using Dielectric Grease PN 2871329 lubricate brush end bushing and install shims 8 Align brush plate and install cover and screws 9 Lightly grease pinion shaft and install pinion spring stopper and snap ring 10 Completely assemble starter motor and torque set bolts to 35 52 in Ibs 3 9 5 9 Nm 10 38 11 Install the starter onto the engine case Hand tighten each bolt Torque the bottom bolt first to 9 ft Ibs 12 Nm Then torque the top bolt to the same specification NOTE It is important to tighten the bottom starter bolt first circle as the bottom hole a
59. sily Starter Motor Turns Over Slowly Battery discharged low specific gravity Excessive circuit resistance poor connections see Voltage Drop Test Engine problem seized or binding can engine be rotated easily Faulty or worn brushes in starter motor Starter Motor Turns Engine Does Not Rotate Faulty starter drive Faulty starter drive gears or starter motor gear Faulty flywheel gear or loose flywheel Voltage Drop Test The Voltage Drop Test is used to test for bad connections When performing the test you are testing the amount of voltage drop through the connection A poor or corroded connection will appear as a high voltage reading Voltage shown on the meter when testing connections should not exceed 1 VDC per connection or component To perform the test place the meter on DC volts and place the meter leads across the connection to be tested Refer to the voltage drop tests in the Starter System Testing Flow Chart Voltage should not exceed 1 DC volts per connection Starter Motor Removal Disassembly NOTE Use electrical contact cleaner to clean starter motor parts Some solvents may leave a residue or damage internal parts and insulation 1 Remove the starter from the engine 2 Remove the two bolts washers and sealing O Rings Inspect O Rings and replace if damaged 10 35 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc E
60. st The system is continuously running diagnostic checks and monitoring factors such as battery voltage ground speed and engine speed In the event an internal or external issue that affects the EPS system is detected the system will illuminate a fault indicator and transition to a normal mechanically coupled steering system The system is Polaris Digital Wrench compatible for simplified diagnostics and system troubleshooting through the vehicle s diagnostic port With the engine off and the key on the power steering unit will operate for up to five minutes After the five minutes you will need to cycle the key switch and restart the engine to regain power steering operation The Power Steering 30A Fuse If the fuse fails the Power Steering Malfunction Indicator Light MIL on the instrument cluster will illuminate During this time the vehicle will have no power steering operation You will be able to connect and communicate with the vehicle s Engine Controller but not the Power Steering Controller while using Digital Wrench NOTE DO NOT SPLICE OR CUT INTO THE CAN CIRCUITS A WARNING Electronic Power Steering EPS units are not interchangeable between ATV and RANGER product lines NOTE See Chapter 5 Body Steering Suspension for power steering unit removal and installation procedures 10 42 Wire Color Functions WIRE COLOR ORANGE 2 Pin BROWN 2 Pin ORANGE 8 Pin YELLOW 8 Pin
61. tester on the VDC position place the tester s black lead on the battery negative and the red lead on the battery positive Reading should be 12 4 V D C or greater Yes q Remove battery and properly service Install fully charged shop battery to continue test Disconnect 2 wire connector at the solenoid Using a multi meter connect the black meter lead to the Orange Green harness wire and the red meter lead to the White Red harness wire Apply gt the brake and turn ignition switch to the start Check for voltage at the chassis 20 Amp fuse and then check for voltage entering the ignition switch Battery voltage should be present If battery voltage is present at the ignition switch but not the solenoid replace the switch NOTE The brake MUST be applied when performing these tests position Meter should read battery voltage Test the start solenoid by powering the solenoid via the 2 wire connection With the solenoid energized resistance should read about 0 50 10 between the two terminals If resistance measurement is out of specification replace the starter solenoid see Starter Solenoid Bench Test Yes Voltage Drop Testing Reconnect the solenoid Connect the tester black lead to the battery positive and the red lead to the solenoid end of the battery to solenoid wire Turn the ignition key to the start position Reading shou

2011-2012 RANGER 800 XP / HD / CREW / 6x6

Contents

Download Pdf Manuals

Related Search

Related Contents