Electrical

ELECTRICAL

CHAPTER 15

ELECTRICAL

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

COMPONENTS UNDER HOOD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

COMPONENTS BEHIND DASH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

COMPONENTS UNDER CENTER CONSOLE / PASSENGER SEAT BASE . . . . . . . . 10.3

ELECTRONIC CONTROL UNIT (ECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4

GLOW PLUGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

TWO SPEED MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5

REAR DIFFERENTIAL SOLENOID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

DIFFERENTIAL SOLENOID OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

DIFFERENTIAL SOLENOID CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

ALL WHEEL DRIVE (AWD) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

AWD / 2WD / TURF SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

AWD COIL OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6

VERSION

PUMP NEUTRAL (TREADLE) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

ENGINE OIL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

IGNITION (KEY) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10

HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11

WORK, TILT LOCK AND AUX SWITCHES (HD AND HDPTO) . . . . . . . . . . . . . . . . . . 10.12

WORK, TILT LOCK AND AUX. SWITCH TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12

WORK, TILT LOCK AND AUX. SWITCH WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . 10.12

BOX LIFT SWITCH (HD AND HDPTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

BOX LIFT SWITCH TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

BOX LIFT SWITCH WIRING DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13

HYDRAULIC OIL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14

HYDRAULIC TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14

PTO CONTROLS (HDPTO MODEL ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

PTO ENGAGEMENT SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

PTO CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

SEAT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15

INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

INSTRUMENT CLUSTER PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18

INFORMATION DISPLAY AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18

PRELIMINARY

HEADLIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25

HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25

HEADLIGHT HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26

HEADLIGHT HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26

TAIL LIGHT / BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27

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ELECTRICAL

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28

COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28

COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29

FAN CONTROL CIRCUIT OPERATION / TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29

FAN CONTROL CIRCUIT BYPASS TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29

HVAC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30

HVAC SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30

HVAC CONTROL CIRCUIT OPERATION / THEORY . . . . . . . . . . . . . . . . . . . . . . . . . 10.31

AC SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31

BLOWER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31

TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31

FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32

FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKERS / TVS DIODES . . . . . . . . . . . 10.33

FUSE, RELAY, CIRCUIT BREAKER AND TVS DIODE LOCATIONS. . . . . . . . . . . . . 10.33

RELAY BOX DETAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34

RELAY POWER FLOWCHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36

FUSE / RELAY BOX DETAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38

EXTERNAL RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41

CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41

CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41

CHARGING SYSTEM ALTERNATOR WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . 10.42

VERSION

GENERAL BATTERY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44

BATTERY REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44

BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44

BATTERY TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44

BATTERY CONDUCTANCE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.45

BATTERY CHARGING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46

BATTERY TERMINAL BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.46

STARTER SYSTEM AND WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.47

STARTER SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48

STARTER MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.49

STARTER MOTOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.49

STARTER MOTOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.51

STARTER MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.52

STARTER SOLENOID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.53

STARTER SOLENOID BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.53

DIGITAL WRENCH® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54

DIGITAL WRENCH® DIAGNOSTIC SOFTWARE OVERVIEW. . . . . . . . . . . . . . . . . . 10.54

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54

ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54

GUIDED DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54

DIGITAL WRENCH® COMMUNICATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54

DIAGNOSTIC CONNECTOR LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.55

DIGITAL WRENCH® SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . 10.55

PRELIMINARY

SPECIAL TESTS MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.60

DATA ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.61

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ELECTRICAL

Components Under Hood GENERAL INFORMATION

Special Tools

The following electrical components can be accessed under the hood.

Part Number Tool Description

PV-43568 Fluke™ 77 Digital Multimeter

PV-43526 Connector Test Kit

2870630 Timing Light

• Headlight Connectors

• Terminal Block

Components Behind Dash Panel

2460761

2871745

PU-50296

Hall Effect Sensor Probe Harness

Static Timing Light Harness

Battery Conductance Analyzer



(MDX-610P)

PU-49466 Relay Bypass

The following electrical components can be accessed with the upper dash panel removed.

• Instrument Cluster (Speedometer)

• AWD/2WD/TURF Switch

• Headlight Switch

SPX Corp: 1-800-328-6657 or http://polaris.spx.com/

Electrical Service Notes

Keep the following notes in mind when diagnosing an electrical problem:

• 12 VDC Accessory Power Points

• Ignition Key Switch

VERSION

• Cargo Box Lift Circuit Breaker

• Refer to wiring diagram for electrical component resistance specifications.

• When measuring resistance of a component that has a resistance value under 10 Ohms, remember to subtract meter lead resistance from the reading.

Connect the leads together and record the resistance. The resistance of the component is equal to tested value minus the lead resistance.

• Become familiar with the operation of your meter.

Be sure leads are in the proper jack for the test being performed (i.e. 10A jack for current readings). Refer to the Owner’s Manual included with your meter for more information.

• 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

Components Under Center Console /

Passenger Seat Base

The following electrical components can be accessed with the passenger seat base / center console removed.

• Battery / Battery Cables

• Fuse / Relay Boxes

• Terminal Block

• ECU

• Digital Wrench® Diagnostic Connector

• Transient-Voltage Suppression (TVS) Diodes

15

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.

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ELECTRICAL

ELECTRONIC CONTROL UNIT (ECU)

Located under the middle passenger seat on the BRUTUS model and under the center console on the BRUTUS HD and HD

PTO

models, the ECU manages the fuel pull solenoid, the fuel hold solenoid, the fuel pump, and glow plug operation. The ECU stores the logic for hot lamps, radiator fan, 2-speed shift strategy, AWD control, and starter lockout.

Digital Wrench® also reports on the following items:

• AWD and Diff Lock Status

• Battery Voltage

• Brake Switch (on/off)

• Cooling Fan Relay Driver

• Crankshaft Signal Present

• Engine RPM, Temperature and Run-Time

• Fuel Pump (on/off)

• Gear Switch Voltage

• PTO Status / RPM

• Seat Switch (Operator Present) Input / Output

• Treadle / Pump Neutral Sensor Status

• Two Speed Shift Coil Duty Cycle

• Vehicle Speed

ECU Removal

1. Turn the ignition switch to the off position.

2. Remove the passenger seat or center console.

3. Remove the four plastic rivets retaining the ECU to the base.

4. Disconnect the harness to the ECU and remove the

ECU from the vehicle.

CRANKSHAFT POSITION SENSOR

(CPS)

The CPS is used to provide the ECU with engine speed for

AWD operation and to determine PTO speed.

CPS Location

The CPS is located on the transmission side of the engine on the bell housing.

CPS Testing

1. Disconnect the main harness from the sensor harness pigtail.

2. Connect an ohmmeter between the CPS pin terminals shown below and compare to the spec below. The reading should be taken at room temperature.

VERSION

CPS Resistance Specification:

1000

 ± 10%

PRELIMINARY

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ELECTRICAL

GLOW PLUGS

The glow plugs are located on the engine assembly below the valve cover. The valve cover will need to be removed if the glow plugs are to be tested or replaced.

Glow Plug Testing

1. Disconnect the air intake hose going to the valve cover.

2. Remove the nine 10 mm bolts retaining the valve cover to the engine and lift the valve cover off.

3. Remove the nuts (Item 1) retaining the sub-harness to the glow plugs.

TWO SPEED MANIFOLD

The two speed manifold modifies pressure and flow to the shift plate in the pump motor depending on selected gear and speed. There are two distinctive ramps per drive gear.

Two Speed Manifold Location

The two speed manifold is located under the driver’s seat above the fuel tank in the same block as the steering priority and steering relief valves.

VERSION

Two Speed Manifold Testing

The two speed manifold should be tested for proper operation using Digital Wrench®. Go to the Special Tests menu - Output State Control and select Command a Duty

Cycle.

4. Using an ohmmeter, put the red lead on the glow plug connector and the black lead to engine ground.

Glow Plug resistance: 0.4 Ω

5. If glow plugs require replacement, torque glow plug fasteners to specification.

= T

Glow Plug

M10: 12 ft-lbs

PRELIMINARY

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REAR DIFFERENTIAL SOLENOID

Differential Solenoid Overview

The differential solenoid is located on the rear portion of the transmission case. The solenoid actuates a shift fork with an engagement dog, which locks and unlocks the rear differential. Reference Chapter 9 for more information.

ALL WHEEL DRIVE (AWD) SYSTEM

AWD / 2WD / TURF Switch

1. Disconnect the AWD / 2WD / TURF switch harness by depressing the connector locks and pulling on the connector. Do not pull on the wiring.

2. Test between the 2 sets of outputs (AWD / 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.

• Move the switch to 2WD. There should be no continuity between pins 1 and 2; 2 and 3.

• Move the switch to TURF. There should be continuity between switch pins 1 and 2.

Differential Solenoid Circuit Operation

NOTE: Pins 7 and 3 provide power and ground for the AWD indicator. Pins 1 and 7 provide power and ground for the Turf indicator.

VERSION at the hub coil and if the criteria is met, the ECU provides a ground path on brown/white. The AWD icon should display on the instrument cluster.

The Rear Diff Solenoid Relay is attached to the rear portion of the main frame and can be accessed by tilting the rear cargo box.

AWD Testing

1. Verify AWD switch is functional and that a minimum of 11 volts is present at the hub coil.

When the switch is pushed to activate “TURF”, a ground signal is provided to the ECU from the AWD switch.

2. Verify AWD hub coil is functional. Test the AWD hub coil using an ohm meter. See specifications below:

Depending on engine speed and gear position criteria, the

ECU energizes the Rear Diff Solenoid Relay allowing it to enable the differential solenoid.

Test Ohms Reading

Connect Meter

Leads To:

If the rear diff fails to switch from operational modes:

AWD Coil GY to BN/WH ~ 24

 ± 5%

AWD Coil GY to Ground Open Line (OL)

• Check the solenoid and relay connectors. Look for loose wires or bad connections.

• Check for power from the relay connector, to

CAUTION

3. Verify the wiring harness, wiring, connectors, ensure the solenoid has power to be activated.

• Check the AWD switch wires for loose connector pins and grounds are undamaged, clean and connected properly.

PRELIMINARY

IMPORTANT: Verify all wires and wiring connections have been tested properly before suspecting a component failure. 80% of electrical issues are caused by bad/failed connections and grounds.

Do not power the solenoid with 12 Volts for more than 1 second, or damage may occur to solenoid.

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AWD / Turf Circuit Break-Out Diagram

ELECTRICAL

VERSION

PRELIMINARY

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ELECTRICAL

FUEL SOLENOID

The pull coil is a strong coil that is energized to pull the solenoid contacts together. The hold coil is a much weaker coil that only needs to be strong enough to keep the contacts closed.

VEHICLE SPEED SENSOR

The speed sensor is located on the ride side of the transmission, accessed through the right rear wheel well.

Vehicle Speed Sensor Testing

Fuel Solenoid Location

The fuel solenoid is located on the engine block below the air intake duct.

Fuel Solenoid Pull Coil Testing

1. Disconnect the fuel solenoid.

2. Ohm across pins P1 and P3 on the solenoid. and remove the sensor from the transmission.

2. Connect the wires from the Static Timing Light

Harness (PN 2871745) 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.

Pull Coil: 0.33 Ω

Fuel Solenoid Hold Coil Testing

1. Disconnect the fuel solenoid.

2. Ohm across pins P2 and P3 on the solenoid.

Hold Coil: 24.5 Ω

PRELIMINARY

NOTE: Some units may have a shim between the speed sensor and the gearcase housing. If a shim is removed, a shim should be installed on reassembly.

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TRANSMISSION (GEAR POSITION)

SWITCH

Transmission (Gear Position) Switch

The transmission switch is located on the right side of the transmission. The switch can be accessed through the right rear wheel well opening.

1. Disconnect the transmission switch harness by lifting the connector lock and pulling on the 2-pin connector.

Do not pull on the wiring.

2. Test transmission switch for continuity in each gear position and compare to the specifications below.

PUMP NEUTRAL (TREADLE) SWITCH

The Pump Neutral Switch is used for starting, speed sensor, and AWD logic. The switch is normally closed

(treadle pedal is not being pushed).

Pump Neutral Switch Location

The Pump Neutral Switch is located under the plastic covering on the hydraulic pump housing.

Pump Neutral Switch Testing

1. Put the cargo box in the fully open position.

2. Disconnect the main harness from the pump neutral switch flying lead.

3. Using an ohmmeter, with the treadle pedal in the neutral position there should be continuity between the black (A) and blue (C) wires on the pump neutral switch wiring.

VERSION

PRELIMINARY

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ELECTRICAL

ENGINE OIL PRESSURE SWITCH

The engine oil pressure switch closes and sends a ground signal to the ECU if engine oil pressure is below the 8 PSI.

The ECU then signals the instrument cluster to display the low oil pressure indicator light and the LCD displays “CK

ENG”. The switch is normally open.

Engine Oil Pressure Switch Location

The engine oil pressure switch (Item 1) is located on the engine block below the throttle cable bracket.

1

IGNITION (KEY) SWITCH

Ignition Key Switch Testing

1. Disconnect the key switch harness by lifting the connector lock and pulling on the connector. Do not pull on the wiring.

2. 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.

VERSION

Engine Oil Pressure Switch Testing

1. Disconnect the pink wire on the vehicle harness going to the engine oil pressure switch.

2. Start the engine and let it run for at least 5 seconds.

3. Ohm the connection on the sensor to chassis ground.

It should read OL. Continuity would indicate low oil pressure or a faulty switch.

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ELECTRICAL

HEADLAMP SWITCH BRAKE LIGHT SWITCH

The headlamp switch is located on the upper dash panel.

Headlamp Switch Testing

• 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; 4 and 5.

The brake light switch senses pressure off the brake master cylinder to determine if the brake pedal is depressed. The switch is normally open.

1. Disconnect the headlamp switch harness by depressing the connector locks and pulling on the connector. Do not pull on the wiring.

2. Test between the 3 sets of outputs (HIGH / LOW /

OFF). If any of the tests fail, replace headlamp switch assembly.

Brake Light Switch Location

The brake light switch (A) is located on the front brake line banjo bolt of the master cylinder. The brake switch can be accessed through the front left wheel well opening.

Brake Light Switch Testing

1. Disconnect the vehicle harness (Item 1) from the brake switch (Item 2).

1

2

VERSION

2. Connect an ohmmeter across switch contacts.

Reading should be infinite (OL).

3. Apply foot brake and check for continuity between switch contacts. If there is no continuity or if resistance is greater than 0.5 ohms, clean the switch contacts and re-test. Replace switch if necessary.

4. Refer to Chapter 14 if replacing the brake switch, as the brake bleeding procedure will need to be performed.

15 light the switch lamp.

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ELECTRICAL

WORK, TILT LOCK AND AUX SWITCHES (HD AND HD

PTO

)

Work, Tilt Lock and Aux. Switch Testing

1. Remove the plastic rivets retaining center console cover to get access to the work, tilt lock and aux. switches.

2. Disconnect the harness to each switch.

3. Using an ohmmeter, test the pins on the switch according to the wiring diagram.

Work, Tilt Lock and Aux. Switch Wiring Diagram

VERSION

15.12

PRELIMINARY

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BOX LIFT SWITCH (HD AND HD

PTO

)

Box Lift Switch Testing

1. Remove the upper dash cover to get access to the box lift switch.

2. Disconnect the harness to the box lift switch.

3. Using an ohmmeter, test the pins on the switch according to the wiring diagram.

Box Lift Switch Wiring Diagram

ELECTRICAL

VERSION

PRELIMINARY

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ELECTRICAL

HYDRAULIC OIL SWITCH

The hydraulic pressure switch will check if the hydraulic oil filter is plugged and illuminate the Oil Pressure indicator and “CK HYD” will display on the LCD. The switch is normally closed.

Hydraulic Oil Switch Location

The hydraulic oil switch (Item 1) is located on the hydraulic oil filter housing behind the driver’s seat.

Hydraulic Oil Switch Testing

1. Disconnect the vehicle harness from the hydraulic oil switch.

2. Connect an ohmmeter from chassis ground to the switch contact. The switch is closed when adequate pressure is present. An OL reading would indicate a plugged hydraulic oil filter or a bad switch.

1

2

HYDRAULIC TEMPERATURE

SENSOR

The hydraulic temperature sensor (Item 2) will check hydraulic oil temperature at the hydraulic filter housing. If the temperature gets too high, the Oil Temperature indicator will illuminate on the instrument cluster and “CK

HYD” will display on the LCD.

Hydraulic Temperature Sensor Location

The hydraulic temperature sensor (Item 2) is located on the hydraulic filter housing under the driver’s seat between the cargo box and the cab.

Hydraulic Temperature Sensor Testing

1. Disconnect the vehicle harness from the hydraulic temperature sensor.

2. Using an ohmmeter, place one lead on a pin on the

VERSION

32° F (0° C) ~815 Ω

77° F (25° C) ~1000 Ω

212° F (100° C) ~1700 Ω

Function

Hydraulic Lamp On Solid

Hydraulic Lamp Off

Hydraulic Lamp Starts Blinking

Hydraulic Lamp Stops Blinking

Cooling Fan On

Cooling Fan Off

Engine Shutdown

(when temp is sustained for 60 sec)

Temperature

197° F (92° C)

185° F (85° C)

201° F (94° C)

199° F (93° C)

190° F (88° C)

185° F (85° C)

205° F (96° C)

PRELIMINARY

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Seat Switch PTO CONTROLS (HD

PTO

MODEL ONLY)

The PTO system is designed so the PTO clutch will disengage when the PTO Engagement switch is ON and the driver is not sitting on the seat.

PTO Engagement Switch

The PTO Engagement Switch is located on the center console.

Located under the driver’s seat base, the seat switch disengages the PTO clutch when pressure is lost on the driver’s seat.

Seat Switch Testing

1. Lift the driver’s seat and disconnect the seat switch harness.

2. Using a multimeter, check for battery voltage on pin

A on the main harness.

3. Check for less than 1 Ω to ground on pin C of the main harness.

1. Disconnect the PTO Engagement switch harness by lifting the connector lock and pulling on the connector. Do not pull on the wiring.

4. Pin B will be the signal wire. It will have 5 V dc on it when the switch is actuated and ground when the switch is released.

VERSION

2. With the switch if the off position, ohm pins A to C on the switch. The reading should be OL.

3. Engage the PTO switch. There should now be continuity between pins A and C and the reading should be less than 1 Ω.

PTO Clutch

Located between the PTO gearcase and the PTO shaft, the PTO clutch engages when the PTO engagement switch is in the ON position. A minimum of 12 Vdc is required to engage the PTO clutch.

1. Disconnect the PTO clutch from the main harness.

2. Using a ohmmeter, ohm the two pins going to the PTO clutch.

15

Connect Meter

Leads To:

Ohms Reading

PTO Clutch Blk to Blk ~ 2.4

 ± 5%

PTO Clutch Blk to Ground Open Line (OL)

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INSTRUMENT CLUSTER

Overview

The instrument cluster displays critical vehicle information to the user. Reference the following page for display functions and descriptions.

VERSION

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Rider Information Display

11. Hour Meter - Illuminates when the display (2) is showing hours.

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.

12. Low Oil Pressure Indicator - LED icon illuminates when low engine oil pressure is sensed or the hydraulic filter is plugged. If the engine oil pressure is low, “CK ENG” will display on the LCD. If the hydraulic filter is plugged, “CK HYD” will display.

13. Gear Position Indicator - Displays gear selector position.

1. Vehicle Speed Display - Analog display of vehicle speed in MPH or km/h.

H = High

2. Information Display Area - Service Info - LCD display of the service hour interval, total vehicle miles or km., total engine hours, a trip meter, engine RPM and engine temperature.

L = Low

N = Neutral

4. High Beam Indicator - LED icon illuminates whenever the Headlamp switch is in the high beam position.

P = Park

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.

-- = Gear Signal Error (shifter stuck between gears)

14. Power Steering System MIL - N/A on this model.

VERSION ready to start.

16. Seat Belt Indicator - LED icon illuminates for several

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.

seconds when the key is turned to the ON position.

The lamp is a reminder to the operator to ensure all riders are wearing seat belts before operating the vehicle.

6. Clock / PTO RPM - Displays current time in either 12hour or 24-hour formats. When the PTO is engaged,

PTO RPM will be indicated instead of the clock.

17. AWD/TURF Indicator - Illuminate to indicate how many drive wheels are active. This will tell you if you are in AWD, 2WD, or Turf.

7. Engine / Hydraulic Fluid Temperature Indicator -

LED icon illuminates when the ECM determines the engine or hydraulic oil is too hot. “CK ENG” will display on the LCD if the engine oil temperature is too high and “CK HYD” will display if the hydraulic oil is too hot.

The indicators will initially be on solid to indicate overheating. The indicators will start blinking if a severe overheating condition exists.

18. ADC Indicator - N/A on this model.

19. 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 startup once it reaches 0.

8. PTO Indicator - PTO is engaged when this is illuminated. PTO RPM will be displayed in the Clock field (6) ONLY when engine RPM is displayed in the

Information Display Area (2).

PRELIMINARY management system.

10. Unit Lock - N/A on this model.

20. Unit of Measurement - Indicates the measurement

(Trip 1, Trip 2, KM, MI, RPM) being displayed in the

Information Display Area (Item 2).

15

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Instrument Cluster Pinouts

FUNCTION

CAN High

CAN Low

Switched Power (Vdc)

Constant Power (Vdc)

Ground

High Beam Input

Park Brake

Engine Oil Pressure Input

Fuel Level Sensor

Mode Function Input

Hydraulic Oil Pressure Input

Hydraulic Oil Temperature Input

Treadle Reverse Input

10

11

13

14

15

16

8

9

4

5

PIN

1

2

3

Information Display Area

The LCD portion of the instrument cluster is the information display area which displays the following information: odometer, trip meter, RPM, battery voltage, engine temperature, air temperature, engine hours, trouble codes, service interval, and clock.

Units of Measurement

Distance

Miles (MPH)

Temperature Fahrenheit

Time

12-Hour Clock

Kilometers (KM/H)

Celsius

24-Hour Clock

To change between Standard and Metric units of measurement, follow these steps:

1. Turn the key to the OFF position.

2. Press and hold the MODE button while turning the key

VERSION

15.18

and advance to the next display option.

5. Repeat the procedure to change remaining display settings.

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Odometer Tachometer (RPM)

ELECTRICAL

The odometer records and displays the total distance traveled by the vehicle. The odometer can not be reset.

Trip Meter

Engine RPM can be displayed digitally.

PTO RPM, when engaged, is indicated after the gear icon and will only display when engine RPM is shown.

Engine Temperature

VERSION

The trip meter records the miles 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.

Engine Hours

Shows current engine temperature. Engine temperature can be displayed in ° F or ° C. Refer to “Units of

Measurement” to change the format.

Clock

Total hours can not be reset.

The clock displays the time in a 12-hour or 24-hour format.

Refer to “Units of Measurement” to change the format

(Standard 12-hour / Metric-24 hour). To set the clock:

1. Toggle the MODE button until the odometer is displayed.

2. Press and hold the MODE button until the hour segment flashes. Release the button.

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15

ELECTRICAL

3. With the segment flashing, tap the MODE button to advance to the desired setting.

4. Press and hold the MODE button until the next 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 clock mode.

Battery Under / Over Voltage

This warning indicates that the vehicle is operating at an

RPM too low to keep the battery charged, the electrical loads are too high, or there is a charging system failure.

Battery Voltage Low

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:

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.

Battery Voltage High

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.

Check Hydraulic

will display “OV” and provide the present battery voltage.

If voltage rises above 16.5 volts, LCD backlighting and icons will turn off.

Indicates too low of hydraulic oil pressure caused by a plugged/blocked hydraulic oil filter or too high of hydraulic oil temperature. The Oil or Temperature light will illuminate along with this message.

Check Engine / Trouble Code Display

The diagnostic mode is accessible only when the check engine MIL has been activated.

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Use the following procedure to display diagnostic trouble codes that were activated during 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 codes are not displayed, use the MODE button to toggle until “CK ENG” displays on the information display area.

8. If more than one code exists, press the MODE button to advance to the next trouble code.

9. To exit the diagnostic mode, press and hold the

MODE button or turn the ignition key OFF once the codes are recorded.

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.

4. The first number (located far left) can range from 0 to

9. This number represents the total number of trouble codes present (example: 2 means there are 3 codes present).

5. The second number (located top right) can be 2 to 6 digits in length. This number equates to the suspected area of fault (SPN).

6. The third number (located bottom right) can be 1 to 2 digits in length. This number equates to the fault mode

(FMI).

VERSION

PRELIMINARY

7. Use the Diagnostic Trouble Code Table on the following pages for a description of each code.

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15

ELECTRICAL

Diagnostic Trouble Codes

Component Condition SPN FMI

Digital Wrench®

P-Code

Vehicle Speed Signal

Engine Temperature Sensor (ECT)

System Power



(Battery Potential / Power Input)

Data Erratic or Intermittent (or missing)

Voltage Too High

Voltage Too Low

Temperature Too High

Voltage Too High

Voltage Too Low

Gear Sensor Signal Voltage Too Low

Crankshaft Position Sensor (CPS) Plausibility Fault

Rear Differential Output

Driver Circuit Open / Grounded

Driver Circuit Short to B+

Driver Circuit Grounded


Fan Relay Driver Circuit

Fuel Pump Driver Circuit





PTO Solenoid Driver Circuit

ECU 3.3V Output Supply Voltage

ECU 5V Output Supply Voltage

Hydraulic Oil Temperature Sensor





Voltage Too High

Voltage Too Low

Voltage Too High

Voltage Too Low

Temperature Too High

Hydraulic Over-temp Shutdown

Received Hydraulic Oil Temp Has Error


All Wheel Drive Control Circuit



520207

(AWD)

Glow Plug Relay Driver Circuit


Driver Circuit Short to B+ 520272


Fuel Pull Solenoid Relay Driver

Circuit

Driver Circuit Short to B+ 520273


84

110

168

4

16

3

4

2

3

523

636

4

2

P0916

P0335

746

5

3

P1691

P1692

1071

4

5

3

4

P1693

P1481

P1483

P0503

P0118

P0117

P0217

P0563

P0562

1347

1888

3597

3598

3

4

3

4

4

5

5

3

3

4

P0230

P0232

P0231

P1310

P1311

P1312

P16A2

P16A1

P16A9

P16A8

5536

3

4

5

3

4

16

0

19

5

3

4

5

P1218

P121A

P121B

P1836

P1835

P1834

P1385

P1384

P1383

P125A

P125D

P125C

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Component Condition

Two Speed Shift Coil Driver Circuit



Operator Presence Switch

Hydraulic Oil Pressure Sensor /

Switch


Voltage Too High

Hydraulic Oil Filter Plugged

Engine Oil Pressure Sensor / Switch Oil Level Low

SPN

520274

524070

524075

524076

FMI

17

17

5

3

4

3

ELECTRICAL

Digital Wrench®

P-Code

P1750

P1751

P1752

P251C

P150F

P151F

VERSION

PRELIMINARY

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15

ELECTRICAL

Instrument Cluster Removal

NOTE: Do not allow alcohol or petroleum products to come in contact with the instrument cluster lens.

1. Remove the push rivets (Item 1) and upper dash panel (Item 2) from the vehicle.

Instrument Cluster Installation

1. 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.

1

2

3

2. Disconnect the wire harness connector (Item 3) from the back side of the instrument cluster.

3. Push the instrument cluster (Item 4) out of the lower dash panel, while securely holding the panel and rubber mount (Item 5).

indexing key on the rubber mount is lined up with the keyway in the dash panel.

3. 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 on the instrument cluster.

4. Connect the wire harness to the instrument cluster.

5. Install the upper dash panel and push rivets.

4

5

6 snap-on assembly and is a serviceable part.

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HEADLIGHTS

Headlight Adjustment

1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall.

6. Once the beam is set to the position, tighten the adjustment screw. Repeat the procedure to adjust the other headlight.

X

1

25 ft. (7.6 m)

WARNING

Due to the nature of light utility vehicles and where they are operated, headlight lenses become dirty. Frequent washing is necessary to maintain lighting quality. Riding with poor lighting can result in severe injury or death.

X

2

8 in. (20 cm)

2. Measure the distance from the floor to the center of the headlight (X

1

) and make a mark on the wall at the same height (X

2

).

3. With the vehicle in Park, start the engine and turn the headlight switch to the LOW position.

4. The most intense part of the LOW 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. Remove the hood and locate the adjustment screw

(Item 1) on the side of the headlight housing (Item 2).

Adjust the beam to the desired position by loosening the adjustment screw and moving the lamp to the appropriate height.

2

Headlight Bulb Replacement

1. Remove the hood from the front cab.

2. Locate the bulb on the back side of the headlight housing and Disconnect the harness (Item 3) from the bulb. Be sure to pull on the connector, not on the wiring.

VERSION

3

3. Turn the bulb counterclockwise and remove it from the headlight housing.

1

15

PRELIMINARY

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ELECTRICAL

4. Install the new bulb into the housing and rotate it clockwise 90° to lock it in place.

5. Install the harness onto the new headlight bulb and install the hood.

7. Carefully push on the face of the headlight housing to disengage the housing tabs from the front fascia brackets.

8. Remove the headlight housing from the vehicle.

Headlight Housing Removal

1. Remove the hood from the front cab.

2. Remove the Torx-head screw and push rivet retaining the upper right portion of the front fender.

Headlight Housing Installation

1. Install the headlight housing by pressing the housing tabs back into the front fascia brackets.

2. Secure the headlight housing with the rubber O-rings

(Item 3) on each side. Install the adjustment screw

(Item 4).

NOTE: Be sure to twist the O-rings upon installation as shown below.

3

VERSION

4

3. Carefully lift up the front fender far enough to access the entire headlight housing.

4. Disconnect the harness from the bulb (see “Headlight

Bulb Replacement”).

5. Remove the O-rings (Item 1) from each side of the headlight housing.

3. Connect the harness to the bulb.

4. Install the Torx-head screw and push rivet retaining the upper right portion of the front fender.

5. Install the hood.

6. Adjust headlights using the “Headlight Adjustment” procedure.

2

1

PRELIMINARY

6. Remove the adjustment screw (Item 2).

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ELECTRICAL

TAIL LIGHT / BRAKE LIGHT

LED Lamp Replacement

1. Open the rear tailgate.

2. Remove the two screws retaining the LED lamp assembly.

3. Remove the LED lamp from the rear cargo box and disconnect the tail light / brake light wire harness.

VERSION

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.

4. Install the new LED lamp assembly by reversing this

PRELIMINARY

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ELECTRICAL

COOLING SYSTEM

Cooling System Break-Out Diagram

VERSION

15.28

PRELIMINARY

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ELECTRICAL

Coolant Temperature Sensor

The Coolant Temperature Sensor is found on the top right side of the engine by the water pump housing.

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.

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.

1. With the engine and temperature sensor approximately 77

°

F (25

°

C), disconnect the harness.

Fan Control Circuit Bypass Test

2. With a multimeter set to ohms, place the meter leads onto the sensor contacts.

3. Use the Temperature / Resistance table to determine if the sensor needs to be replaced.

Condition Approx. Ω Temperature

1. Disconnect harness from coolant temperature sensor.

VERSION other components are working properly.

Engine Shutdown

(temp. is sustained for

25 seconds)

1.22 k

 ± 2%

248° F

(120° C)

3. If the fan does not run or runs slowly, check the fan motor wiring, ground, motor condition, circuit breaker and relay for proper operation. Repair or replace as necessary.

Coolant Hot Lamp

(Blinking)

240° F

(116° C)

1.30 k

 ± 2% 4. 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 Hot Lamp

(On Solid)

1.45 k

 ± 2%

230° F

(110° C)

Cooling Fan On

Cooling Fan Off

2.80 k

3.40 k

 ± 2%

 ± 2%

194° F

(90° C)

182° F

(83° C)

Room Temperature

System Capacity

29.9 k

 ± 2%

77 °F

(25 °C)

Brutus / Brutus HD - 6.2 qts (5.9 L)

Brutus HD

PTO

- 6.9 qts (6.5 L)

Radiator Cap Relief

Pressure

13 PSI

15 malfunctions the radiator fan will default to 'ON' while the engine is running.

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ELECTRICAL

HVAC SYSTEM

HVAC System Break-Out Diagram

VERSION

15.30

PRELIMINARY

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ELECTRICAL

HVAC Control Circuit Operation / Theory

Power is supplied to the HVAC system through the 30 amp fuse found in its own fuse holder outside of the main fuse box under the center console. The condenser fan is powered by a 20 amp circuit breaker through the condenser fan relay.

The HVAC relay is powered by the 30 Amp HVAC fuse. When they key is in the ON position, the HVAC relay is energized.

Power is sent on the Red/Green wires to the blower switch, the temperature knob (temp pot 10k) and the water valve.

Power only travels from the blower switch to the AC switch on the white wire when the knob is in the low, medium or high setting. If the AC switch is ON, power is sent out on the blue wire to power the condenser fan relay and the thermostat on the AC evaporator. The evaporator thermostat will send power on the white wire to the HPCO (high pressure cut-out) switch located in the AC hose. The switch is normally closed. When the switch is closed, power is sent to the AC compressor. When the pressure in the AC line gets too high, the switch opens and the compressor cycles off. The condenser fan will always be running when the AC system is on and it is powered by a 20 Amp circuit breaker just outside the relay box.

As the temperature knob is moved towards the warm setting, the voltage through the potentiometer is interpreted by the water valve to control the flow of warm water through the heater core to warm the air.

AC Switch

The AC Switch can be tested using an ohmmeter.

1. Disconnect harness from AC Switch.

2. With the meter in the ohms mode, place the leads on pins P1 and P3.

3. With the switch off, the reading should be OL.

4. With the switch on the reading should be less than 1 Ω.

Temperature Control

The Temperature Control potentiometer can be tested using an ohmmeter.

VERSION

2. With the meter in the ohms mode, place the meter leads onto the potentiometer flying lead contacts.

3. Use the table to determine if the switch needs to be replaced.

Blower Switch

The Blower Switch can be tested using an ohmmeter.

1. Disconnect the harness going to the Blower Switch.

2. With the meter in the ohms mode, place the meter leads onto the switch contacts.

3. Use the table to determine if the switch needs to be replaced.

Knob Position

Full Cold

Between Cold/Hot

Full Hot

Any Position

Pins

A to B

A to B

A to B

A to C

Ohms Reading

~ 81.5k



~ 86.5k



~ 91.5k



~ 10k



CAUTION

Keep hands away from fan blades during operation. Serious personal injury could result.

15

PRELIMINARY

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FUEL SENDER

Testing

1. Remove the fuel level assembly from the fuel tank

(see Chapter 4 “Fuel Pick-Up / Sending Unit

Removal”).

2. Using an Ohm meter, measure the resistance of the fuel sender as shown below.

3. Allow the sender float to sit in the empty position and compare to specification.

Fuel Sender - Empty: 6 ± 2



4. Slowly move the sender float to the full position and compare to specification.

Fuel Sender - Full: 102 ± 2



5. If the readings are out of specification, or if the reading is erratic or LCD display “sticks”, check the following before replacing the fuel level assembly:

• Loose float

PRELIMINARY assembly is faulty. Replace the fuel level sender assembly (see Chapter 4).

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FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKERS / TVS DIODES

Fuse, Relay, Circuit Breaker and TVS Diode Locations

Located under the center console, the fuses provide overload protection for wiring and components. The relays assist with high load component operation. A separate relay and 40 amp circuit breaker protects the cooling fan motor circuit and can be found outside of the relay / fuse boxes. On PTO models, a separate HVAC relay and 30 amp HVAC fuse can be found in a fuse holder just outside the relay / fuse boxes. If equipped, the box lift relay and 20 Amp circuit breaker is located under the upper dash cover near the box lift switch.

VERSION

Component Descriptions

1. Radiator / Cooling Fan Relay 7. Relay Block - houses the fuel pull, ECM, PTO, glow plug, fuel hold, and chassis relays. All relays in this box are interchangeable.

2. HVAC Relay - HD and HD

PTO

models only. Provides power to the heating and air conditioning system.

8. TVS (transient-voltage-suppression) Diode - used to protect electrical components from voltage spikes.

3. HVAC 30 Amp Fuse - HD and HD

PTO

models only.

Provides power to the HVAC Relay

4. Radiator / Cooling Fan 40 Amp Circuit Breaker

PRELIMINARY starter and tilt lock relays as well as the glow plug, drive, fuel hold, fuel pull, ECU, PTO, hydro, acc. and

• PTO (HD

PTO

model only)

• Hydraulic Solenoid (HD and HD

PTO

model only)

• Fuel Solenoid / Fuel Pump

• Start Solenoid light fuses.

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Relay Box Detail

VERSION

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ELECTRICAL

FUEL PULL SOLENOID RELAY provides power to the pull coil side of the fuel solenoid.

P

IN

30 Red

C

87 White

FUEL PULL SOLENOID RELAY

OLOR

F

UNCTION

86

Red / Dark

Blue

12 V switched power from ECM relay.

85 Brown / Blue ECU ground input to enable relay.

12 V circuit powered by the 30

Amp Fuel Pull Solenoid fuse through the 30 Amp Chassis fuse.

Provides 12 V power for fuel pull solenoid coil.

PTO RELAY provides power to the PTO Clutch and Tilt

Lock Relay.

PTO RELAY (HD

PTO

model only)

P

IN

C

OLOR

F

UNCTION

86 White / Orange 12 Vdc from PTO switch.

85 White / Black ECU ground input to enable relay.

30

87

Red / Dark

Blue

Red / Dark

Blue

12 Vdc power from PTO fuse through PTO splice #1.

Provides 12 Vdc power for PTO splice #2 for clutch engagement and tilt lock relay.

ECM RELAY provides power to the ECU, Fuel Pull relay,

Fuel Hold relay, Glow Plug relay, Cooling Fan relay, Seat

Pressure switch (HD

PTO

model only), and Two Speed

Manifold.

ECM RELAY

P

IN

86

85

C

OLOR

Red / Dark

Blue

Dark Green /

Yellow

F

UNCTION

20 Amp ECU fuse protected 12

Vdc constant battery voltage.

ECU ground input to enable relay.

30 Red / White

87 Red / White



Provides 12 Vdc power to the

ECU relay B+ splice.

GLOW PLUG RELAY provides power to the Glow Plugs.

P

IN

86

C

OLOR

Red / Dark

GLOW PLUG RELAY

VERSION

Blue

12 Vdc switched power from ECU relay.

85 Brown / Green ECU ground input to enable relay .

30 Red

87 Black / Red

30 Amp Glow Plug fuse protected

12 Vdc constant battery voltage.

Provides 12 Vdc power for glow plug operation.

FUEL HOLD SOLENOID RELAY provides power to the fuel solenoid hold coil and the fuel pump.

FUEL HOLD SOLENOID RELAY

P

IN

C

OLOR

F

UNCTION

86 Red/Dark Blue

12 V switched power from ECM relay.

85

Grey/Dark

Green


30 Red

87 Red

12 V circuit powered by the 20

Amp Fuel Hold Solenoid fuse pump and fuel solenoid hold coil.

CHASSIS RELAY provides power to the following systems:

• Lights (Headlights / Taillights)

• Drive (AWD / TURF)

• Accessory (12V Receptacles / Accessory Options)

CHASSIS RELAY

P

IN

C

OLOR

15

86 Orange

85 Brown

30 Red

87 White

F

UNCTION

12 Vdc power input from key switch to enable relay.

Relay coil constant ground.

BUSS Bar - 12 Vdc constant battery voltage

Provides 12 Vdc power for lights, drive and accessory circuits.

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Relay Power Flowcharts

Fuel Pull Relay, PTO Relay, Fuel Hold Relay

VERSION

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ECM Relay, Glow Plug Relay, Chassis Relay

VERSION

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ELECTRICAL

Fuse / Relay Box Detail

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Fuse / Relay Box Detail

TILT LOCK RELAY provides power to the hydraulic control valve tilt lock when activated to prevent tilting of the hydraulic attachment when the PTO switch is engaged or when the tilt lock switch is turned on.

TILT LOCK RELAY

P

IN

C

OLOR

86

Red / Dark

Blue

85 Brown

30 Beige / Black

87 Beige / Black

87A Dark Green

F

UNCTION

12 Vdc switched power from PTO fuse through the PTO switch.

Chassis Ground

Provides 12 Vdc power for tilt spool lock when the tilt lock switch is engaged (relay unswitched)

Provides 12 Vdc power for tilt spool lock when PTO is engaged.

(relay switched)

Power to control valve to lock the tilt spool. (relay unswitched)

STARTER RELAY provides power to the starter solenoid.

STARTER RELAY

P

IN

86

85

C

OLOR

White / Red

(154)

White / Red

(E201)

F

UNCTION

12 Vdc switched power from key switch


30 Red / White

87

White / Red

(111)



Provides 12 Vdc power for starter solenoid operation.

CONDENSER FAN RELAY provides power to the air conditioner condenser fan.

CONDENSER FAN RELAY (HD

PTO

model only)

P

IN

86 Blue

C

OLOR

85 Brown

F

UNCTION

Chassis ground to enable relay.

30 White / Black

20 Amp circuit breaker protected

12 Vdc constant battery power.

87 White / Grey

Provides 12 Vdc power for condenser fan operation.

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15

ELECTRICAL

External Relays

HVAC RELAY

is found under the center console outside of the relay boxes. The HVAC relay provides power to the following:

• Blower Switch

• Temperature Control Switch

• Water Valve

HVAC RELAY (HD

PTO

model only)

P

IN

C

OLOR

86 Orange

85 Brown

30

87

Red / Dark

Blue

Red / Dark

Green

F

UNCTION

12 Vdc switched power

Chassis ground.

30 Amp HVAC fuse protected 12

Vdc constant battery power.

Provides 12 Vdc power for HVAC operation.

CARGO BOX LIFT RELAY

provides power to the cargo box lift actuator and is mounted on the sub-harness for the cargo box lift switch under the upper dash cover.

CARGO BOX LIFT RELAY

P

IN

C

OLOR

F

UNCTION

86 Orange / White

12 Vdc switched power from 20A

Accessory fuse

85 Brown

30 Red

87 Red

Chassis ground through the front terminal block.

20 Amp Circuit Breaker protected


Provides 12 Vdc power to the Box

Lift switch for lift operation.

RADIATOR FAN RELAY

is found outside the relay boxes in the center console and provides power to the cooling fan

COOLING FAN RELAY

P

IN

C

OLOR

F

UNCTION

86

Red / Dark

Blue

BUSS Bar - 12 Vdc switched power from EFI relay.

85 Brown / Red ECU ground input to enable relay.

30 Red

87 Orange/Black

40 Amp circuit breaker protected


Provides 12 Vdc power for fan operation.

REAR DIFF SOLENOID RELAY

provides power to the rear differential solenoid and is located below the cargo box by the rear frame support.

C

OLOR

VERSION

Brown Relay coil ground.

Dark Green / White ECU input to enable relay.

Red / Dark Green

10-Amp fuse protected 12 Vdc battery voltage.

Red

Blue

Relay switched power to operate the Rear Diff Solenoid.

Ground to energize the Rear Diff

Solenoid.

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CHARGING SYSTEM

The BRUTUS alternator is rated 12v, 90A, 1215 watts (at

13.5 V nominal voltage).

Charging System “Break Even” Test

CAUTION

Current Draw - Key Off

CAUTION

Do not allow the battery cables to become disconnected while the engine is running. Follow the steps below as outlined to reduce the chance of damage to electrical components.

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.

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.

WARNING

Current Draw Inspection

Key Off connected in series. Damage 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.

30 Amp

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.

Current Draw - Key Off:

Maximum of .01 DCA (10 mA)

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 just above

PRELIMINARY

8. Repeat test, observing ammeter and tachometer.

With lights on, ‘break even’ charging should occur below 2000 RPM.

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Charging System Alternator Wiring Diagram

VERSION

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ELECTRICAL

Alternator Service

• Disconnect the negative (-) battery cable before servicing the electrical system.

• Check electrical harnesses for cracks, abrasions, and damaged or corroded connectors. ALWAYS keep the connectors and terminals clean.

Alternator Installation

1. Position the alternator on the gear case. Loosely reinstall the nut on the gear case stud and the V-belt adjuster bolt.

= T

Alternator Removal

Lower Alternator Mount Bolt

24 ft-lbs (33 Nm)

WARNING

Electrical Shock and Pinch Hazard

1. Disconnect the electrical wires from the alternator.

2. Loosen the alternator adjuster bolt (Item 1) and carefully rotate the alternator towards the cylinder block.

1

2. Reconnect the battery cable to the alternator. Tighten the nut to specification.

= T

Alternator B+ Cable Nut

54 in-lbs (6 Nm)

tension. See Cooling Fan V-Belt adjustment.

= T

Alternator Adjuster Bolt

24 ft-lbs (33 Nm)

2

3. Remove the lower mounting bolt (Item 2) from the alternator. Remove the alternator.

NOTE: Using a non-specified V-belt will cause inadequate charging and shorten the belt life. Use the specified belt.

4. Start the engine. Listen for any unusual sounds from the alternator.

NOTE: Do not operate the engine if the alternator is producing unusual sounds.

15

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General Battery Information BATTERY SERVICE

IMPORTANT: Never attempt to open the battery.

WARNING

CALIFORNIA PROPOSITION 65 WARNING:

Batteries, battery posts, terminals and related accessories contain lead and lead compounds, and other chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. WASH HANDS AFTER HANDLING.

1. Check battery voltage with a volt/ohm meter. A fully charged battery should be 12.8 V or higher.

2. If the voltage is below 12.6 V, the battery will need to be recharged (see “Charging Procedure”).

To service a Maintenance Free battery:

1. Remove battery from the vehicle (see Chapter 2).

WARNING

Battery electrolyte is poisonous. It contains acid!

Serious burns can result from contact with the skin, eyes, or clothing.

2. Test battery with a voltage meter or load tester to determine battery condition. This will determine the length of time required to charge the battery to full capacity. Refer to OCV table (see “OCV - Open Circuit

Voltage Test”).

ANTIDOTE:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil.

Call a physician immediately.

3. Charge the battery as recommended (see “Charging

Procedure”).

VERSION installation procedures.

Battery Off Season Storage

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 closed space. Always shield eyes when working near batteries.

Whenever vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.

Keep out of reach of children.

Battery Specifications

Battery PN 4014132

NOTE: Battery charge can be maintained by using a

Polaris battery tender charger or by charging once a month to make up for normal self-discharge. Battery tenders can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point.

Type Polaris / Flooded-Filled

Voltage 12 Vdc

Battery Testing

Nominal Capacity



@ 20 HR Rate

CCA

Nominal Open

Circuit Voltage

32 AH

575

12.8 Vdc or more.

Whenever a service complaint is related to either the starting or charging systems, the battery should be

PRELIMINARY condition: OCV Test and a Load Test.

Recommended

Charging Rate

1.8A @ 5-10 HR or 6.0A @ 1 HR

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OCV (Open Circuit Voltage) Test

Battery voltage should be checked with a digital multitester. Readings of 12.6 volts or less require further battery testing and charging. See the following chart and

“Load Test”.

Load Test

A battery may indicate a full charge condition in the OCV test, but still may not have the storage capacity necessary to properly function in the electrical system. For this reason, a battery capacity or load test should be conducted whenever poor battery performance is encountered.

NOTE: Maintenance Free batteries should be kept at a high state of charge during storage. If the battery is stored or used at a low state of charge, hard crystal sulfation will form on the plates, reducing the efficiency and service life of the battery.

NOTE: Use a volt/ohm meter to test battery voltage.


To perform this test, use a load testing device that has an adjustable load. Apply a load of three times the amperehour 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.

OPEN CIRCUIT VOLTAGE

State of Charge Maintenance Free

100%

75% Charged

12.8 V and up

12.6 V

50% Charged

25% Charged

0% Charged

12.3 V

12.0 V

11.8 V or less

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 load testing.

VERSION the conductance analyzer when testing 12V Polaris batteries.

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 0.1 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

PRELIMINARY

Polaris MDX-610P

SPX PN: PU-50296

15

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ELECTRICAL

Battery Charging Procedure

If battery voltage is 12.6 Vdc or less, the battery may need recharging. When using an automatic charger, refer to the charger manufacturer’s instructions for recharging.

Recommended Charging Rate: 1 hour @ 6-10 Amps.

Do not exceed 10 amps when charging the battery.

NOTE: Charge the battery using an automatic charger that will not exceed 14.6 Vdc. An automatic charger will signal when charging is complete.

NOTE: Allow the battery to stand disconnected for at least 1-2 hours after being properly charged. If the voltage drops below 12.6 volts, charging was ineffective or the battery needs to be replaced.

Battery Terminal Block

A terminal block located under the hood (Item 1) provides easy hookup for accessories. On the non-PTO models, you will need to run a positive and negative wire from the rear terminal block to the front terminal block in order to make the front terminal block functional. The rear terminal block (Item 2) can be found under the seat next to the battery.

1

WARNING

An overheated battery could explode, causing severe injury or death. Always watch charging times carefully.

Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.


State of

Charge

Voltage (DC) Action

Charge

Time

100% 12.8 or more

None, check again in 3 months

None

Required

75% - 100% 12.6 - 12.8

May need slight charge

3 - 6 hrs

50% - 75% 12.3 - 12.6

Needs Charge 5 - 11 hrs

25% - 50%

0% - 25%

12.0 - 12.3

Needs Charge

12.0 or less Needs Charge

At least

13 hrs

At least

20 hrs

VERSION

2

= T

NOTE: Follow the charger instructions supplied by

Terminal Block Nuts:

the manufacture regarding the order or connections, switch positions and when to connect the charger to an outlet.

PRELIMINARY

20-25 in-lbs (2.3-2.8 Nm)

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ELECTRICAL

VERSION

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ELECTRICAL

Starter System Troubleshooting

VERSION

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ELECTRICAL

Starter Motor Removal

1. Disconnect the positive and negative battery cables.

2. Using a 10mm wrench, remove the nut retaining the battery cable to the starter motor.

3. Remove the lower starter mounting bolt (Item 1) first.

3. Remove the two nuts (Item 3) retaining the solenoid switch assembly to the pinion housing. Remove the solenoid switch assembly and dust covers. Remove the plunger and torsion spring (Item 4) from the pinion housing.

2

4

3

1

4. Remove the upper starter mounting bolt (Item 2) and nut.

5. Remove the starter motor from the flywheel housing.

Starter Motor Disassembly

1. Scribe alignment marks across all mating joints prior to removing that part.

2. Disconnect the field wire from the solenoid switch.

4. Remove the two bolts (Item 5) retaining the rear cover

VERSION

5

6

5. Remove the two through bolts retaining the rear cover and remove the rear cover.

6. Pull the brush springs up using a brush spring puller.

On the negative side, bring the brush spring into contact with the side of the brushes to hold the brushes clear of the commutator surface. On the positive side, remove the brushes from the brush holder assembly.

PRELIMINARY

15

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ELECTRICAL

7. Remove the brush plate and holder (Item 7).

9

13. Remove the pinion stop (Item 13) and pinion clutch assembly (Item 14) from the pinion shaft (Item 15).

14

8

7

15

13

8. Pull the field assembly (Item 8) off from the armature assembly (Item 9).

9. Remove the armature from the intermediate housing.

10. Remove the intermediate housing, gear and pinion shaft assembly (Item 10) from the pinion housing.

Disengage it from the shift lever as it is removed.

11. Remove the shift lever (Item 11), pin and spacer (Item

12).

14. Remove the snap ring (Item 16) and pull out the pinion shaft (Item 17), planetary gears (Item 18), washers and reduction gear (Item 19) from the intermediate housing (Item 20).

VERSION

16

21

19

11

12

22

17

18

15. Inspect the intermediate bushing (Item 21) and armature bushings (Item 22) and replace if worn or damaged.

10

12. Pull the pinion stop down to expose the retaining ring.

Using a flat-blade screwdriver, remove the retaining ring from the pinion shaft.

PRELIMINARY

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Starter Motor Testing

Armature Coil Continuity Test

Check for continuity between the commutator segments using a multimeter. There should be continuity present between any two segments. If the continuity is present, replace the armature.

Field Coil Continuity Test

Check for continuity between the field coil terminals using a multimeter. There should be continuity present. If there is not continuity, replace the field coil assembly.

Armature Coil Insulation Test

Check for continuity between a commutator segment and the shaft or armature using a multimeter. The multimeter should not indicate continuity. If there is continuity present, replace the armature.

Field Coil Insulation Test

VERSION coil assembly.

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ELECTRICAL

Brush Holder Insulation Test

Check for continuity between each brush holder and the base using a multimeter. There should not be continuity present. If there is continuity, replace the brush holder.

Starter Motor Installation

1. Install the starter motor onto the flywheel housing.

2. Hand tighten the upper starter motor bolt and nut.

3. Install the lower mounting bolt and torque to specification.

= T

Upper Starter Mounting Bolt and Nut:

40 ft-lb (53 Nm)

Lower Starter Mounting Bolt:

32 ft-lb (45 Nm)

Pinion Clutch Assembly Inspection

Manually rotate the pinion clutch assembly. It should rotate freely in the drive direction and should lock by turning it in the opposite direction. Replace the pinion clutch assembly if the results are different.

Slide the pinion clutch assembly on the pinion shaft. It should slide smoothly on the shaft. Rust, too much grease or damage could prevent the pinion clutch from sliding smoothly. If the pinion clutch assembly does not slide smoothly, clean the shaft and pinion clutch assembly or replace the damaged component causing the binding.

IMPORTANT: Tighten the lower starter bolt first, as the bottom hole acts as a pilot hole to properly align the starter drive with the flywheel. This helps prevent binding and starter damage.

specification.

VERSION

= T

Upper Starter Mounting Bolt and Nut:

7 ft-lbs (10 Nm)

5. Install the starter motor battery cable to the starter solenoid stud. Torque nut to specification.

15.52

PRELIMINARY

= T

Starter B+ Cable Nut

54 in-lbs (6 Nm)

6. Reconnect the battery.

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ELECTRICAL

Starter Solenoid Operation

To energize the Starter Solenoid the following must occur:

• The unit in Park or Neutral gear selection OR the treadle pedal must be in the neutral position.

• The key switch must be turned to the “start” position to provide 12V power to the starter solenoid 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.

Starter Solenoid Bench Test

Test the start solenoid by powering the solenoid using battery voltage for a maximum of 5 seconds. With the solenoid energized, you should get continuity between the battery positive post of the solenoid and the starter housing

VERSION

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ELECTRICAL

DIGITAL WRENCH®

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 allows the technician to perform the following tests and observations:

• View or clear trouble codes • Perform guided diagnostic procedures

• Analyze real-time engine data

• Reflash ECU calibration files

• Create customer service account records

• Perform output state control tests (some models)

Special Tools

DIGITAL WRENCH® DIAGNOSTIC SOFTWARE

Digital Wrench® Diagnostic Kit

PU-47063-B (listed above) INCLUDES:

Fluke 73 Digital Multi-Meter or Fluke 77 DMM

Laptop or Desktop Computer

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 original ECU is transferred to the replacement ECU.

PART NUMBER

PU-47063-B

Digital Wrench® Software: PU-48731

Standard Interface Cable: PU-47151

SmartLink Module Kit: PU-47471

VERSION

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/.

Refer to procedure and carefully follow all instructions provided in Digital Wrench®.

Guided Diagnostics

PRELIMINARY

In addition, guided diagnostics are also available for many other electrical sub systems.

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Diagnostic Connector Location

BRUTUS - The diagnostic plug (Item 1) is located under the passenger seat in the center tray by the ECU.

Digital Wrench® Serial Number Location

Open the configuration screen by clicking on the wrench icon. Serial number is located on right side of the screen.

1

BRUTUS HD / HD

PTO

- Located under the center console.

It may be accessed without removing the center console by removing the cup holder (Item 2) and removing the connector (Item 3) from the retainer (Item 4).

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.

VERSION

2

Version

2. Proceed to http://polaris.diagsys.com to see if a newer update is available.

3

4

PRELIMINARY

Digital Wrench Update

3. If a newer update is available, it should be

15

downloaded before using Digital Wrench® (see

“Digital Wrench® Updates”).

IMPORTANT: Always operate with the latest update.

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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.

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.

distributors can access the dealer website.

1. Log on to www.polarisdealers.com.

2. Locate the “Service and Warranty” drop-down menu.

3. Click on “Digital Wrench Updates”.

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

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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.

4. The Digital Wrench® portal website should appear in a new web browser.

5. Click on “Digital Wrench Version Updates”.

Digital Wrench Update

version installed before adding an update. Updates will not install if you are using an older version loaded on your PC.

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NOTE: Versions and updates are subject to change.

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Digital Wrench® Feature Map

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Engine Controller Reprogramming (Reflash)

Process Overview

The reprogramming feature is in the Special Tests menu on the Digital Wrench® 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.

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

.

• 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 online help is the most current and complete information available. This should be your first step until you are familiar with the process.

• 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.

IMPORTANT: Replacement ECUs require a reflash for them to work.

Reprogramming (Reflash) Tips:

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• 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 12.8 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 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.

• 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.

• OBTAINING THE LATEST UPDATE:

Reprogramming updates are provided periodically and contain the most recent calibrations (see

“Digital Wrench® Updates”).

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Scanners, Tool Bars, etc. may clog up memory if running in the background and make it harder for

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 the diagnostic software to operate.

and loaded into Digital Wrench®.

2. Connect SmartLink Module cables to PC and vehicle.

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3. Open the Digital Wrench® program.

4. Select the model year, product line and vehicle description by selecting the “Change Vehicle Type” icon.

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 numbers in a request code.

Authorization Key goes here after obtained from the dealer website

Copy Request Code to obtain Authorization Key

5. Select the “Special Tests” icon.

NOTE: Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen.

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6. Select “Engine Controller Reprogramming”.

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.

“Service and Warranty”

“Reflash Authorization”

10. Enter or paste (CTRL+V) the Request Code into the box.

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Enter the

“Request Code”

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11. Select the same file type from the list that you selected previously while in Digital Wrench®. Enter the VIN along 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 the vehicle or PC during the process.

Enter ALL the information and click on the “Authorize” button

12. An “Authorization Key” will appear in the upper left corner of the screen. Copy (CTRL+C) this key exactly as it appears.

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.

The following items are available on the Special Tests menu (red toolbox):

Vehicle Historical Information - indicates total engine run-time, RPM and speed histograms and engine overheats.

Output State Control - Command the ECU to run the following tests:

“Authorization Key”

13. Enter or paste (CTRL+V) the Authorization Key in the box located on the Digital Wrench® screen. Click the

‘Continue’ button and follow instructions provided on the screen to complete reprogramming procedure.

• Differential Unlock Solenoid Test

• Fan Driver Test

• Front Wheel Drive Output Test

• Fuel Pull Solenoid Test

• Fuel Pump Test

• Glow Plug Relay Test

• PTO Solenoid Relay Test (if equipped)

• Reverse Alarm Test (if equipped)

Enter the

“Authorization Key”

• Two Speed Shift Coil Test

PRELIMINARY program to input the model number into the new ECU.

PTO Enable/Disable Procedure - Enable / Disable PTO engagement until this procedure is run again.

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Engine Controller Reprogramming - This program will update or install a calibration in the ECU. It is required to be performed on all new ECU’s AFTER the ECU

Replacement procedure is performed.

Vehicle Information - This brings up the software calibration numbers for the ECU and instrument cluster.

Feature Configuration/Registration - This is only used when registering Digital Wrench® and is not specific to this unit.

Data Items

The following items can be monitored on Digital Wrench®:

• Engine RPM

• Engine Temperature

• Engine Temperature Sensor Voltage

• Battery Voltage

• Fuel Pump Status

• Crankshaft Sensor Signal Present

• Vehicle Speed

• Cooling Fan

• Differential Lock

• AWD

• Treadle Sensor

• Seat Sensor

• PTO RPM

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