Snowmobile Polaris PRO X (2003 year). Manual - part 72

ELECTRICAL

8.10

Unregulated Voltage - continued

Turn the multitester dial to the Volts AC (V

µ) position.

Disconnect the alternator to main harness connector at
engine.

Connect one of the tester leads to the yellow alternator
wire and the other lead to the brown alternator wire.
NOTE: On floating alternators, the yellow/red stator
wire should connect to the brown stator wire. If it does
not, the system will not have a ground and will not
operate.

10. Start the engine. While observing the voltage reading,

increase the engine speed to about 3000 RPM.
Readings of between 15 and 45 VAC are considered
normal.

Short Circuit Current (AC Amp Test)

Turn multitester dial to A

µ.

Connect red lead to 10A terminal.

Connect black lead to Com (--) meter terminal.

Disconnect lighting/charge coil wires from system.
Connect meter leads to coil wires leading to stator coils.

Start and idle engine. Readings should be above 5
amps. Refer to Amps AC on page 8.9.

Regulated Voltage

Connect the alternator to main harness connector.

Insert one of the tester leads along the side of the yellow
regulator wire connector between the insulation and the
terminal.

Ground the other tester lead.

Start engine and observe headlight output. Increase
engine RPM. If the headlights seem dim above 3500
RPM, let the engine return to idle and disconnect the
yellow wire from the regulator. Carefully observe the
voltage reading.

Do not allow voltage to increase above

14.0 volts.

Slowly increase RPM. Voltage above 12 volts at 2500 -
3000 and a bright headlight, indicates a good lighting
coil. Voltage below 10 volts at 3000 indicates excessive
system loads, poor flywheel magnets, lighting coil
problems, or wires harness problems.

Check for

partially grounded (shorted) yellow wire.

Reconnect the yellow regulator wire and increase the
RPM. If the headlight was bright with the regulator
disconnected and dim when connected at the same
RPM, the regulator or regulator ground is at fault.

15-45

VAC

ELECTRICAL

8.11

Alternators

The 6 pulse alternator system is the number of AC sine waves created by the alternator in one revolution of the
crankshaft. For example, in a 6 pulse system, the alternator will create 6 pulses, or 6 complete AC sine waves, in
one crankshaft revolution. The tachometer reads these sine waves, therefore giving you accurate RPM readings.
A 3 pulse tachometer cannot be used on a 6 pulse system. If this is done, the tachometer will read double RPM.
Refer to the following text for applications.

Polaris Snowmobiles:

All Polaris Domestic twin cylinder engines

6 pulse

. . . . . . . . . . . . . . . . . . . . . . . . . .

Fuji 3 cylinder engine

6 pulse

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuji Fan Cooled EC45/55PM

6 pulse

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tachometers:

Tachometers for snowmobiles will have an identification marking on the back side. For example: The tachomter
for a 600 RMK will have “6 pulse” (or 6P) written on it.

6-Pulse

ELECTRICAL

8.12

Exhaust System Temperature sender - 440 Pro X

Temp sender
The temp sender that is on the 440 Pro X will read the exhaust temperature and adjust the
timing according to the temperature range.

To Test the sensor:

Unplug sensor. At room temperature the temperature sender will have a HIGH resistance
(may read Open Line (OL)) depending on your meter.

As the pipe gets hotter, the resistance keeps lowering resulting in optimum timing for a
given RPM and pipe temperature,
If the sender resistance is not responding to pipe heat the sensor may need to be re-
placed.

LOW PIPE TEMP = HIGH RESISTANCE
MEDIUM PIPE TEMP = MEDIUM RESISTANCE
HIGH PIPE TEMP = LOW RESISTANCE

Measure resistance here

440 Pro X Tuned Pipe

ELECTRICAL

8.13

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

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