Snowmobile Polaris High Performance (2001 year). Manual - part 89

ELECTRICAL

8.15

Headlight Bulb Filament Continuity Test

Turn the Multitester dial to the ohms (

) position.

Disconnect the wire harness from the headlight bulb.

Viewing the back of the bulb with the terminal blades at
the 9, 12 and 3 o’clock position, connect the black
multitester lead to the 9 o’clock blade.

Touch the red tester lead to the 12 o’clock terminal and
then to the 3 o’clock terminal, noting the resistance
value of each. A reading of between 2 and 5 ohms is
good. An open reading indicates a bad element.

Hi/Lo Beam Switch Testing

Set the multitester dial to the ohms (

) position.

If the Hi/Lo switch has not been removed from the
machine, disconnect the switch to harness plug-in
connector.

With the Hi/Lo switch in the Lo beam position, check the
resistance between the yellow and the green switch
wires. The reading should be less than .4 ohms.

Turn the Hi/Lo switch to the Hi beam position and the
multitester should indicate an open circuit (OL)
reading.

Move one of the tester leads from the green to the red
switch wire. The multitester should now read less than
.4 ohms.

Turn the Hi/Lo Switch back to the Lo beam position and
the meter should again read an open circuit (OL).

Seat Harness Troubleshooting

Remove the taillight lens.

Remove the two taillight bulbs and the brakelight bulb.

Separate the seat harness from the main harness by
unplugging the connector at the right rear of the tank.

With the multitester dial set on ohms (

) connect either

meter test lead to the brown seat harness wire.

Touch the other tester lead to first the yellow wire and
then the orange wire. Observe the readings. Readings
other than an open circuit (O.L.) indicate a shorted
harness or bulb socket. NOTE: The bulb socket tangs
sometimes short to ground with the bulb removed.

Check between the yellow and orange wires in the
same manner to check for a short between the brake
and running lights. If damaged wiring is found, remove
the seat.

Tip the seat over and remove the right side seat cover
staples. Locate and repair the harness problem.

Reinstall the staples and re-check the seat harness.

Low

High

Grn

Yel

Yel/Rd

High/Low Switch

ELECTRICAL

8.16

Ignition Switch Testing (Non-Electric Start)

Set the multitester dial to the ohms (

) position.

Connect one of the tester leads to either of the switch
terminals and the other tester lead to the other switch
terminal.

With the switch off, the reading should be less than .4
ohms. With the switch on, the reading must be an open
circuit (OL).

Check the resistance between each of the switch
terminals and the switch body. With the switch still in the
on position, there must be an open circuit (OL) reading.
Readings other than those listed indicate a defective
switch.

Ignition Switch Testing (Electric Start Models)

NOTE: Refer to the appropriate model and year wiring
diagram for ignition switch wire colors and connections.

Disconnect wires. Set the multitester dial to the ohms
(

) position.

With the key in the off position, check the resistance
between the G (Ground, brown) terminal and the M
(Mag, black) terminal. This reading must be less than .4
ohms.

Turn the key to the on position. The multitester should
now read an open circuit (OL).

Move the tester lead from the G terminal to the switch
housing and re-check the reading. It should also be an
open circuit (OL).

Place one of the tester leads on the B (Battery, red)
terminal and the other tester lead on the S (Starter, blue)
terminal. With the key in the on position, there must be
an open circuit (OL) reading.

Turn the key to the start position. The reading should be
less than .4 ohms. Readings other than the ones listed
indicate a defective switch.

Blk

Brn

Off

Ignition Switch

Brn

Blk

R/W

Off

Start

Ignition Switch - Electric Start

ELECTRICAL

8.17

Coolant High Temperature Indicator Testing

Yel

Temp

Blk/W

Circuit
Power
In

Engine
Ground

Ground the Black/White wire here
(with the engine running) to test
the light.

The indicator light is controlled by a temperature/warning switch installed into the engine cooling system. When
engine coolant temperature reaches approximately 205



F, the switch closes, completing the circuit through the

indicator light to ground. the system should be tested periodically for proper operation.

Lamp Circuit Test

Remove wire from temperature sensing switch located under thermostat housing.

With engine idling, ground wire to engine. The temperature warning lamp on the console should light. If not,
replace the lamp assembly or inspect wiring for shorts or open circuit.

Temp Light Temperature Sensor Test

The temperature/warning switch is normally open.

Set the multitester on the ohms (

) scale.

Disconnect the lamp wire.

Connect one test probe to the switch terminal and the other to engine ground. The meter should show an open
circuit (OL). This indicates a normally open switch. If the switch were heated to approximately 205



F, the

contact in the switch would close and the reading would be less than .4 ohms.

CAUTION:

If attempting to heat the sensor to close the contacts, heat only in a water bath. Never subject the sensor to an
open flame to attempt to close the contacts as sensor damage will result.

ELECTRICAL

8.18

Speed Control Assurance Operation

Off Idle Switch

Idle Switch

Plungers
Outward

Throttle Control
Cutaway

Engine Ground

Ignition Primary

Auxiliary Kill
Switch Contacts

Insulator

Conductor

The speed control assurance consists of two series connected switches. If one or both switch plungers are posi-
tioned inward, the circuit is open and the engine will run.

At idle, with the throttle lever properly adjusted, the bottom switch circuit is open and the plunger is inward. The
top switch circuit is closed, and the plunger is outward. The speed control circuit is open, allowing the engine to
run.

As the throttle lever is actuated to an off idle position, the top switch circuit is opened (plunger in) and the bottom
switch circuit is closed (plunger out). The speed control circuit is still open, allowing the engine to run.

In the event the carburetor or controls malfunction and allow the throttle cable to become slack, the circuit will
close (both switch plungers out), grounding the ignition system and causing the engine to stop.

Speed Control Assurance Adjustment

Throttle lever free play must always provide a specified
clearance between throttle lever (A) and throttle block (B).
This clearance is controlled by the throttle cable sleeve(s)
and the idle speed screw(s).

If the idle speed screw(s) is adjusted inward and the cable
sleeve(s) is not adjusted to take up the throttle lever to
throttle block clearance, the engine may misfire or kill upon
initial throttle opening.

CAUTION:

After any idle speed adjustments are made, the throttle lever to throttle block clearance and oil pump adjustment
must be checked and adjusted.

NOTE: When adjustments are made on models which have more than one carburetor, refer to Section 6, Car-
buretion, for proper carburetor synchronization adjustments.

.010-.030

〉

(.25-.8 mm)

Throttle Lever Freeplay -

Regular Throttle - .010 - .030

〉

(.25 - .8 mm)

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