chapter 4 electronic fuel injection - brp tuningfiles.brptuning.ru/polaris/manuals/2009/polaris rzr...

ELECTRONIC FUEL INJECTION

CHAPTER 4ELECTRONIC FUEL INJECTION

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GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4EFI SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5EFI SYSTEM COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8FUEL LINES - QUICK CONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9

ELECTRONIC FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9PRINCIPAL COMPONENTS / EFI OPERATION OVERVIEW. . . . . . . . . . . . . . . . . . . . . 4.9INITIAL PRIMING / STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10

ELECTRONIC CONTROL UNIT (ECU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10ECU SERVICE / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11

TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR (T-BAP) . . . . . . . . . 4.11T-BAP TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11

CRANKSHAFT POSITION SENSOR (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12CPS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12CPS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13

FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17FUEL INJECTOR SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.17FUEL INJECTOR TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.18

FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20FUEL SENDER TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21FUEL PUMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24

THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25TPS LEARN FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25TPS TESTER / REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.25CHECKING TPS READING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.26TPS ADJUSTMENT / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27

ENGINE COOLANT TEMPERATURE SENSOR (ECT) . . . . . . . . . . . . . . . . . . . . . . . . . 4.28ECT SENSOR TEST / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28

IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29IGNITION COIL / HT LEAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29

GENERAL TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30DIAGNOSTIC “BLINK CODES” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30EFI TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31

DIGITAL WRENCH™ OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32DIAGNOSTIC SOFTWARE OVERVIEW / SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . 4.32DIAGNOSTIC SOFTWARE VERSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32ECU REPLACEMENT / GUIDED DIAGNOSTIC AVAILABLE . . . . . . . . . . . . . . . . . . . . 4.32DIGITAL WRENCH™ COMMUNICATION ERRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32DIGITAL WRENCH™ - DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 4.33DIGITAL WRENCH™ SERIAL NUMBER LOCATION / VERSION AND UPDATE ID . . 4.33DIGITAL WRENCH™ UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.34DIGITAL WRENCH™ FEATURE MAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35ENGINE CONTROLLER REPROGRAMMING (REFLASH). . . . . . . . . . . . . . . . . . . . . . 4.36

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GENERAL INFORMATION

Special Tools

Throttle Position Sensor (TPS) Tester - 2201519-A

This tester allows the use of a digital multi-meter to test TPSfunction as well as perform the TPS adjustment procedure.

NOTE: This TPS Tester replaces the existing tester(PU-47082), which included the 4010264 regulator. Ifyour dealership has PU-47082 and 4010264, you DONOT need to order 2201519-A as a replacement.

TPS Tester Wire Harness - PU-47466

This TPS wire harness is part of 2201519-A and incorporatestwo TPS connectors to allow for multi-use applications.

NOTE: Voltage Regulator (547927) is required ifusing TPS Tester Wire Harness (PU-47466). You mayalready have this regulator (marked 4010264) as partof another TPS Tester Kit. If you do not have thisregulator, you must order one from SPX at 1-800-328-6657.

WARNING

* Gasoline is extremely flammable and explosiveunder certain conditions.

* EFI components are under high pressure.Verify system pressure has been

relieved before disassembly.* Never drain the fuel system when the engine is hot.

Severe burns may result .* Do not overfill the tank. The tank is at full capacity when the fuel reaches the bottom of the filler neck.

Leave room for expansion of fuel.* Never start the engine or let it run in an enclosed area.

Gasoline powered engine exhaust fumes arepoisonous and can cause loss of consciousness

and death in a short time.* Do not smoke or allow open flames or sparks in or near

the area where refueling is performed or wheregasoline is stored.

* If you get gasoline in your eyes or if you should swallow gasoline, seek medical attention immediately.

* If you spill gasoline on your skin or clothing, immediately wash with soap and water

and change clothing.* Always stop the engine and refuel outdoors

or in a well ventilated area.

PART NUMBER TOOL DESCRIPTION

2201519-A Throttle Position Sensor (TPS) TesterPU-47466 TPS Tester Wire Harness

547927 TPS Tester RegulatorPU-43506-A Fuel Pressure Gauge KitPV-48656 Fuel Pressure Gauge Adaptor

PU-47063-A

Digital Wrench™ Diagnostic Software(Includes most recent version of software w/serial number, standard interface cable

and SmartLink Module Kit)

PU-47471 Digital Wrench™ SmartLink Module Kit(PU-47470, PU-47469, PU-47468)

PU-47470 Digital Wrench™PC Interface Cable

PU-47469 Digital Wrench™Vehicle Interface Cable

PU-47468 Digital Wrench™SmartLink Module

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TPS Tester Regulator - 547927

This tester regulator regulates the 9 volt battery voltage to a 5volt reference input, required when using the TPS Tester WireHarness (PU-47466).

NOTE: You may already have this regulator (marked4010264) as part of another TPS Tester Kit. If you donot have this regulator, you must order one fromSPX at 1-800-328-6657.

Fuel Pressure Gauge Kit - PU-43506-A

IMPORTANT: The EFI fuel system remains under highpressure, even when the engine is not running.Before attempting to service any part of the fuelsystem, pressure must be relieved (if applicable). TheFuel Pressure Gauge Kit has an integrated pressurerelief valve that can be used to bleed off pressure onceyou have completed the fuel pressure test.

Fuel Pressure Gauge Adaptor - PV-48656

Digital Wrench™ Diagnostic Software - PU-47063-A

This dealer-only software installs on laptop computers equippedwith a CD drive and serial port connection, and is designed toreplace multiple shop tools often used to test EFI components.It also includes step-by-step diagnostic procedures to aidtechnician repair and troubleshooting.

IMPORTANT: If the PC you are using is not equippedwith a 9-pin serial port, a USB to serial port adaptorwill be necessary. A USB to serial port adaptor can bepurchased through DSA at: www.diagsys.com

Digital Wrench™ SmartLink Module Kit - PU-47471

This module kit contains the necessary cables and hardware tocommunicate between the vehicle ECU and the DigitalWrench™ diagnostic software. Polaris dealers can also orderthe following kit components separately: SmartLink ModulePU-47468, Vehicle Interface Cable PU-47469 and PCInterface Cable PU-47470. This module kit is used on all 8 pinconnector-based Polaris EFI systems. This kit is available toPolaris dealers through our tool supplier SPX at (1-800-328-6657) or http://polaris.spx.com

Relief Valve

Adaptor shown isincluded with kit.

Adaptor works withPU-43506-A

Disconnect here and connectin-line w/fuel pump outlet

PU-47468

PU-47469

PU-47470

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Digital Wrench™ - Diagnostic Connector

Located under the dash and accessible from the passenger side.

Digital Wrench™ - Download Website

Located at: www.polaris.diagsys.com

Download Digital Wrench™ Updates:

IMPORTANT: For the most recent information onDigital Wrench™ software and update downloadsplease visit the website: www.polaris.diagsys.com

Service Notes• For more convenient and accurate testing of EFI

components, it is recommended dealers utilize the Digital Wrench™ Diagnostic Software (dealer only), or testing may be done manually using the procedures provided.

• 80% of all EFI problems are caused by wiring harness connections.

• For the purpose of troubleshooting difficult running issues, a known-good ECU from another Polaris RANGER RZR EFI of the same model may be used without damaging system or engine components.

• Never attempt to service any fuel system component while engine is running or ignition switch is "on."

• Cleanliness is essential and must be maintained at all times when servicing or working on the EFI system. Dirt, even in small quantities, can cause significant problems.

• Do not use compressed air if the system is open. Cover any parts removed and wrap any open joints with plastic if they will remain open for any length of time. New parts should be removed from their protective packaging just prior to installation.

• Clean any connector before opening to prevent dirt from entering the system.

• Although every precaution has been taken to prevent water intrusion failure, avoid direct water or spray contact with system components.

• Do not disconnect or reconnect the wiring harness connector to the control unit or any individual components with the ignition "on." This can send a damaging voltage spike through the ECU.

• Do not allow the battery cables to touch opposing terminals. When connecting battery cables attach the positive (red) cable to positive (+) battery terminal first, followed by negative (black) cable to negative (-) battery terminal.

• Never start the engine when the cables are loose or poorly connected to the battery terminals.

• Never disconnect battery while engine is running.

• Never use a battery boost-pack to start the engine.

• Do not charge battery with key switch "on."

• Always disconnect negative (-) battery cable lead before charging battery.

• Always unplug ECU from the wire harness before performing any welding on the unit.

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EFI System Exploded View

1. Electronic Control Unit (ECU)2. Intake Air Temperature / Barometric Air Pressure Sensor (T-BAP)3. Crankshaft Position Sensor (CPS)4. Fuel Injectors5. Fuel Filter6. Fuel Pump / Regulator / Gauge Sender Asm. (Located in tank as an assembly)7. Fuel Rail8. Engine Coolant Sensor (ECT)9. Throttle Position Sensor (TPS)10. Throttle Body11. Ignition Coil12. Spark Plugs

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EFI System Component Locations1. Electronic Control Unit (ECU)

- Located behind the driver’s seat next to the seat beltassembly.

2. Temperature and Barometric Air Pressure Sensor(T-BAP)- Located in the rubber intake boot between the air box andthrottle body.

3. Crankshaft Position Sensor (CPS)- Located in the magneto cover between the engine andtransmission.

4. Fuel Injectors / Fuel Rail- Attached to the fuel rail located in the intake track of thecylinder head.

5. Fuel Pump / Regulator / Fuel Gauge Sender Assembly- Located under the passenger seat and in the fuel tank as acomplete assembly.

ECU

T-BAP

CPS

Fuel Fuel RailInjectors

Fuel Pump Assembly

Located in Fuel Tank

Fuel Pump

Regulator

Pump / Sending Unit

Preliminary Filter

Fine Filter

Fuel LineConnection

Vent LineConnection

Connection

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6. Throttle Body- Located between the rubber air box boot and the rubbercylinder head adaptor.

7. Throttle Position Sensor (TPS)- Located on the right-hand side of the throttle body.

8. Engine Coolant Temperature Sensor (ECT)- Located in the cylinder head next to the thermostathousing. The sensor can be accessed with the driver andpassenger seats and rear service panel removed.

9. Ignition Coil- Located behind the driver’s seat and rear service panel justabove the PVT cover.

Throttle Body

TPS

ECT

Ignition Coil

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FUEL TANKExploded View

RearTank Bracket

Screw

Pad

Fuel Tank

FrontTank Bracket

Gasket

Cap

Hi-TempFlex Conduit

Fuel Pump Asm

Screw

Pad

Quick ConnectFuel Line

Fuel Flow

Fuel Filters Fuel Pump Assembly Quick Connect Fuel Line

Fuel Rail Fuel Injectors

Pressure Regulator

Fuel Tank

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Fuel Lines - Quick ConnectRANGER EFI models use quick connect fuel lines. Refer to thesteps below for fuel line removal.

1. Place a shop towel around the fuel line to catch anydripping fuel. Squeeze the connector tabs together andpush the locking slide back.

2. Pull on the fuel line for removal.

3. To install the line, verify the connector and fuel tank nippleare clean and free of debris.

4. Snap the fuel line back over the nipple and slide the lockingmechanism back into place. Verify the connector tabs snapback into place.

ELECTRONIC FUEL INJECTIONPrincipal ComponentsThe Electronic Fuel Injection (EFI) system is a complete enginefuel and ignition management design. This system includes thefollowing principal components:

• Fuel Pump• Fuel Rail• Fuel Line• Fuel Filter(s)• Fuel Injectors• Pressure Regulator• Throttle Body / lntake Manifold• Engine Control Unit (ECU)• Ignition Coils• Engine Coolant Temperature Sensor (ECT)• Throttle Position Sensor (TPS)• Crankshaft Position Sensor (CPS)• Intake Air Temperature and Barometric Air

Pressure Sensor (T-BAP)• Wire Harness Assembly• Check Engine Light

EFI Operation OverviewThe EFI system is designed to provide peak engine performancewith optimum fuel efficiency and lowest possible emissions.The ignition and injection functions are electronicallycontrolled, monitored and continually corrected duringoperation to maintain peak performance.

The central component of the system is the Bosch EngineControl Unit (ECU) which manages system operation,determining the best combination of fuel mixture and ignitiontiming for the current operating conditions.

An in-tank electric fuel pump is used to move fuel from the tankthrough the fuel line and in-line fuel filter. The in-tank fuelpressure regulator maintains a system operating pressure of 39psi and returns any excess fuel to the tank. At the engine, fuel isfed through the fuel rail and into the injectors, which inject intothe intake ports. The ECU controls the amount of fuel by varyingthe length of time that the injectors are "on." This can range from1.5-8.0 milliseconds depending on fuel requirements. Thecontrolled injection of the fuel occurs each crankshaftrevolution, or twice for each 4-stroke cycle. One-half the totalamount of fuel needed for one firing of a cylinder is injectedduring each injection. When the intake valve opens, the fuel/airmixture is drawn into the combustion chamber, ignited andburned.

Squeeze Connector Tabs

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The ECU controls the amount of fuel being injected and theignition timing by monitoring the primary sensor signals for airtemperature, barometric air pressure, engine temperature, speed(RPM), and throttle position (load). These primary signals arecompared to the programming in the ECU computer chip, andthe ECU adjusts the fuel delivery and ignition timing to matchthe values.

During operation, the ECU has the ability to re-adjusttemporarily; providing compensation for changes in overallengine condition and operating environment, so it will be ableto maintain the ideal air/fuel ratio.

During certain operating periods such as cold starts, warm up,acceleration, etc., a richer air / fuel ratio is automaticallycalculated by the ECU.

Initial Priming / Starting ProcedureNOTE: The injection system must be purged of allair prior to the initial start up, and / or any time thesystem has been disassembled.

If the EFI system is completely empty of fuel or has beendisassembled and repaired:

1. Cycle the key switch from “OFF” to “ON” 6 times,waiting for approximately 3 seconds at each “ON” cycle toallow the fuel pump to cycle and shut down.

2. Once step 1 is completed, turn the key switch to “START”until the engine starts or 5 seconds has passed.

3. If the engine failed to start, repeat step 1 for 2 more cyclesand attempt to start the engine.

If the engine fails to start, a problem may still exist, and shouldbe diagnosed.

NOTE: Accurate testing of EFI components isrecommended utilizing the Digital Wrench™Diagnostic Software (dealer only).

ELECTRONIC CONTROL UNIT (ECU)Operation OverviewThe ECU is the brain or central processing computer of theentire EFI fuel/ignition management system. During operation,sensors continuously gather data which is relayed through thewiring harness to input circuits within the ECU. Signals to theECU include: ignition (on/off), crankshaft position and speed(RPM), throttle position, engine coolant temperature, airtemperature, intake manifold air pressure and battery voltage.The ECU compares the input signals to the programmed mapsin its memory and determines the appropriate fuel and sparkrequirements for the immediate operating conditions. The ECUthen sends output signals to set the injector duration and ignitiontiming.

During operation, the ECU continually performs a diagnosticcheck of itself, each of the sensors, and system performance. Ifa fault is detected, the ECU turns on the “Check Engine” lightin the speedometer and stores the fault code in its fault memory.Depending on the significance or severity of the fault, normaloperation may continue, or "Fail-Safe" operation (slowed speed,richer running) may be initiated. A technician can determine thecause of the “Check Engine” light by initiating the “Blink Code”sequence or by using Digital Wrench™. The ECU requires aminimum of 7.0 volts to operate. The memory in the ECU isoperational the moment the battery cables are connected.

To prevent engine over-speed and possible failure, a rev-limiting feature is programmed into the ECU. If the maximumRPM limit (6500, RZR), (6600, RZR S) is exceeded, the ECUsuppresses the injection signals, cutting off the fuel flow. Thisprocess repeats it self in rapid succession, limiting operation tothe preset maximum.

ECU

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RANGER RZR 800 EFI RPM Limit:

Hard Limit - Injector suppression occurs

• High: (6500, RZR), (6600, RZR S)• Low: (6500, RZR), (6600, RZR S)• Neutral: (6500, RZR), (6600, RZR S)• Reverse: (6500, RZR), (6600, RZR S)• Park: (6500, RZR), (6600, RZR S)

Soft Limit - Timing suppression occurs

• High: (6375, RZR), (6550, RZR S)• Low: (6375, RZR), (6550, RZR S)• Neutral: (6375, RZR), (6550, RZR S)• Reverse: (6375, RZR), (6550, RZR S)• Park: (6375, RZR), (6550, RZR S)

ECU ServiceNever attempt to disassemble the ECU. It is sealed to preventdamage to internal components. Warranty is void if the case isopened or tampered with in any way.

All operating and control functions within the ECU are pre-set.No internal servicing or readjustment may be performed. If aproblem is encountered, and you determine the ECU to befaulty, contact the Polaris Service Department for specifichandling instructions. Do not replace the ECU without factoryauthorization.

The relationship between the ECU and the throttle positionsensor (TPS) is very critical to proper system operation. If theTPS is faulty, or the mounting position of the TPS to the throttlebody is altered in any manner, the TPS must be recalibrated(see “TPS Adjustment” procedure if required).

For the purpose of troubleshooting, a known-good ECU fromanother Polaris RANGER RZR EFI of the same model may beused without system or engine component damage.

ECU Replacement1. Remove the (2) retaining screws holding the ECU.

2. With the Ignition turned off, disconnect the wire harnessfrom the ECU.

3. To install, reverse the procedures and tighten screws tospecification.

TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR (T-BAP)

Operation OverviewMounted in the throttle body intake boot, the T-BAP sensorperforms two functions in one unit.

Air passing through the intake is measured by the T-BAP andrelayed to the ECU. These signals, comprised of separate airtemperature and barometric air pressure readings, are processedby the ECU and compared to its programming for determiningthe fuel and ignition requirements during operation.

T-BAP TestThe T-BAP sensor is a non-serviceable item. If it is faulty, itmust be replaced.

IMPORTANT: The T-BAP sensor requires a 5 VDCinput to operate, therefore the T-BAP sensor shouldonly be tested using the Digital Wrench™ DiagnosticSoftware (dealer only). Refer to the EFI DiagnosticSoftware Manual for more information.

T-BAP Replacement1. Disconnect sensor from engine harness.

2. Using a 3/8” wrench, remove the retaining bolt and removethe sensor from the intake boot.

= T

ECU Retaining Screws10 in. lbs. (1.1 Nm)

T-BAP

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3. Install new sensor using a light coating of oil on the o-ringto aid installation.

4. Torque the T-BAP retaining bolt to specification.

CRANKSHAFT POSITION SENSOR (CPS)

Operation OverviewThe crankshaft position sensor is essential to engine operation,constantly monitoring the rotational speed (RPM) and positionof the crankshaft.

A ferromagnetic 60-tooth ring gear with two consecutive teethmissing is mounted on the flywheel. The inductive speed sensoris mounted 1.0 ± 0.26 mm (0.059 ± 0.010 in.) away from thering gear. During rotation, an AC pulse is created within thesensor for each passing tooth. The ECU calculates engine speedfrom the time interval between the consecutive pulses.

The two-tooth gap creates an “interrupt” input signal,corresponding to specific crankshaft position for PTO cylinder.This signal serves as a reference for the control of ignitiontiming by the ECU. Synchronization of the CPS and crankshaftposition takes place during the first two revolutions each timethe engine is started. This sensor must be properly connected atall times. If the sensor fails or becomes disconnected for anyreason, the engine will quit running.

CPS TestThe CPS is a sealed, non-serviceable assembly. If fault codediagnosis indicates a problem within this sensor, test as follows:

1. Disconnect CPS (3-wire) harness connector on the left-hand side of the vehicle located below the transmission.

2. Connect an ohmmeter between the pin terminals leadingfrom the Yellow and White wires. A resistance value of560Ω ± 10% at room temperature (20°C / 68°F) should beobtained.

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T-BAP Retaining Bolt Torque:29 in. lbs. (3.3 Nm)

T-BAPIntake Boot

Bolt

CPS

CPS Resistance Specification:560Ω ± 10% (20° C, 68° F)

CPSConnector

YellowBlack

White

CPS Harness

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3. If the resistance is correct.- Test the main harness circuit between the sensorconnector terminals and the corresponding pin terminals atthe ECU (see wiring diagram).- Check the sensor mounting, air gap, flywheel ring gear fordamage or runout, and flywheel key. Follow the “CPSReplacement” procedure to inspect CPS and flywheel ringgear for damage.

4. If the resistance is incorrect, follow the “CPS Replacement”procedure.

CPS ReplacementRemoval

1. Safely support the rear of the vehicle off the ground andremove the left-hand rear tire.

2. If not done already; disconnect the CPS harness connector(see illustration under “CPS Test”).

IMPORTANT: In order to remove the CPS, the rearportion of the exhaust system and the mountingbracket between the transmission and rear gearcasewill need to be removed.

3. Remove the exhaust pipe between the elbow pipe and theexhaust silencer. Remove the exhaust silencer.

4. Remove the (3) bolts retaining the front portion of themounting bracket to the transmission. Retain the bolts,washers, and spacers for installation.

5. Remove the bottom bolt that attaches the bracket to the reargearcase through the hole in the frame support as shown.

6. Remove the (2) remaining fasteners that attach the bracketto the side of the rear gearcase.

7. Remove the bolt from the bracket at the front of the reargearcase.

WARNING

Serious injury may result if machine tips or falls.Be sure the vehicle is secure before beginning

this service procedure.

Remove

Remove

Silencer

Elbow

HeaderPipe

Pipe

Standard RZRShown

Rear GearcaseMounting Bolt

TransmissionMounting Bolts

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8. Lift the mounting bracket straight up and out from thevehicle.

9. Using a 5 mm hex wrench, remove the CPS retaining boltand remove the sensor from the magneto housing.

10. Install new sensor using a light coating of oil on the o-ringto aid installation.

11. Torque the CPS retaining bolt to specification.

Installation

IMPORTANT: When reinstalling the transmission torear gearcase mount bracket, it is extremely importantto torque all (7) fasteners to specification. Refer to thefollowing procedure.

NOTE: Special tool (PA-48873) will be required totorque the mounting bracket fasteners when thetransmission and rear gearcase are installed in thevehicle.

1. Clean bolt threads with solvent and allow them to dry.Coat the circumference of the first 4 threads of the boltswith Loctite before installing the bolts.

2. Reinstall mounting bracket and hand tighten the (7) bolts.

3. Torque ALL mounting bracket bolts to specification.

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CPS Retaining Bolt Torque:25 in. lbs. (2.8 Nm)

RemoveBracket

This tool is specifically designed to access the critical transmission to rear gearcase mounting bracket bolts on the RANGER

RZR when the transmission and rear gearcase are installed in the vehicle. This

tool allows for proper torque to be applied to ½” SAE hex head cap screws with limited wrench access. When used at a 90° angle with a torque wrench, no torque multiplier

is necessary.

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Mount Bracket Bolt Torque:23-27 ft. lbs. (31-37 Nm)

Special ToolPA-48873

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4. Using special tool (PA-48873), torque the (3) bolts thatretain the front portion of the mounting bracket to thetransmission.

Upper Transmission Bolt

Middle Transmission Bolt

Bottom Transmission Bolt

5. Remove the special tool and attach an extension to thetorque wrench. Torque the bottom bolt that attaches thebracket to the rear gearcase through the hole in the framesupport.

Bottom Rear Gearcase Bolt

NOTE: Special Tool is not required for this torque.

6. Using special tool (PA-48873), torque the upper (2) boltsretaining the mounting bracket to the rear gearcase. Placethe torque wrench through the rear exhaust silencer openingto gain access to the bolts.

Middle Rear Gearcase Bolt

Torque withan extension

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Upper Rear Gearcase Bolt

7. Torque the remaining bolt that attaches the bracket to thefront side of the rear gearcase.

Front Rear Gearcase Bolt

NOTE: A multi-directional torque wrench is requiredin this application because of the limited access tothis bolt. Check with the manufacturer of yourtorque wrench to see if it can be used to tighten left-hand threaded bolts.

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FUEL INJECTORSOperation OverviewNOTE: All EFI units utilize quick connect fuel lines.

The fuel injectors mount into the cylinder head, and the fuel railattaches to them at the top end. Replaceable O-rings on bothends of the injector prevent external fuel leaks and also insulateit from heat and vibration.

When the key switch is on, the fuel rail is pressurized, andvoltage is present at the injector. At the proper instant, the ECUcompletes the ground circuit, energizing the injector. The valveneedle in the injector is opened electromagnetically, and thepressure in the fuel rail forces fuel down through the inside. The“director plate” at the tip of the injector (see inset) contains aseries of calibrated openings which directs the fuel into theintake port in a cone-shaped spray pattern.

The injector is opened and closed once for each crankshaftrevolution, however only one-half the total amount of fuelneeded for one firing is injected during each opening. Theamount of fuel injected is controlled by the ECU and determinedby the length of time the valve needle is held open, also referredto as the “injection duration” or “pulse width”. It may vary inlength from 1.5-8 milliseconds depending on the speed and loadrequirements of the engine.

Fuel Injector ServiceInjector problems typically fall into three general categories-electrical, dirty / clogged, or leakage. An electrical problemusually causes one or both of the injectors to stop functioning.Several methods may be used to check if the injectors areoperating.

• With the engine running at idle, feel for operational vibration, indicating that they are opening and closing.

• When temperatures prohibit touching, listen for a buzzing or clicking sound with a screwdriver or mechanic's stethoscope.

• Disconnect the electrical connector from an injector and listen for a change in idle performance (only running on one cylinder) or a change in injector noise or vibration.

NOTE: Do not apply voltage directly to the fuelinjector(s). Excessive voltage will burn out theinjector(s). Do not ground the injector(s) with theignition on. lnjector(s) will open/turn on if relay isenergized.

If an injector is not operating, it can indicate either a bad injector,or a wiring/electrical connection problem. Check as follows:

Injector leakage is very unlikely, but in rare instances it can beinternal (past the tip of the valve needle), or external (weepingaround the injector body). The loss of system pressure from theleakage can cause hot restart problems and longer crankingtimes.

Injector problems due to dirt or clogging are unlikely due to thedesign of the injectors, the high fuel pressure, the use of filtersand the detergent additives in the gasoline. Symptoms that couldbe caused by dirty/clogged injectors include rough idle,hesitation/stumble during acceleration, or triggering of faultcodes related to fuel delivery. Injector clogging is usually causedby a buildup of deposits on the director plate, restricting the flowof fuel, resulting in a poor spray pattern. Some contributingfactors to injector clogging include; dirty air filters, higher thannormal operating temperatures, short operating intervals anddirty, incorrect, or poor quality fuel. Cleaning of cloggedinjectors is not recommended; they should be replaced.Additives and higher grades of fuel can be used as a preventativemeasure if clogging has been a problem.

Fuel Fuel RailInjectors

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Fuel Injector TestNOTE: The Bosch harness connector and lockingspring is bonded to the fuel injectors with an epoxymix. DO NOT attempt to disconnect the Boschconnector from the fuel injectors. Damage will occurto the injector and/or harness if attempting toseparate at that location. Separate the fuel injectorfrom the vehicle by disconnecting at the end of theharness as shown in this procedure.

The fuel injectors are non-serviceable. If fault code diagnosisindicates a problem with either injector, test the resistance of thefuel injector(s) by measuring between the two harness pinterminals:

Fuel Injector Replacement1. Be sure the engine has cooled enough to work on.

2. Place a suitable container below the quick connect plug atthe end of the fuel rail. Hold a shop rag over the plug andremove it to depressurize the fuel system.

3. Remove the exhaust pipe between the exhaust silencer andthe elbow pipe to allow better access to the fuel injector rail.

4. Remove the engine breather hose from the valve cover.

5. Remove both driver and passenger seats and remove therear service panel.

Fuel Injector Resistance Specification:13.8 Ω - 15.2 Ω

Disconnect Here

DO NOTDisconnect Here

FuelInjector

Harness

Disconnectand test here

Fuel Rail

Quick ConnectPlug

Remove

Silencer

ElbowHeader

PipePipe

Standard RZRShown

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6. Disconnect the harness for the fuel injector(s) located nextto the ignition coil. Cut the plastic tie strap and push theharness for the fuel injector(s) up over the air box to allowfuel injector removal.

NOTE: The Bosch harness connector and lockingspring is bonded to the fuel injectors with an epoxymix. DO NOT attempt to disconnect the Boschconnector from the fuel injectors. Damage will occurto the injector and/or harness if attempting toseparate at that location. Separate the fuel injectorfrom the vehicle by disconnecting at the end of theharness as shown previous in this procedure.

7. Thoroughly clean the area around the fuel injectorsincluding the throttle body manifold.

8. Using a 6mm hex wrench, loosen the fuel rail mountingscrew from the cylinder head. Carefully pull the rail awayfrom the injectors and remove the injector(s) from thecylinder head along with the harness.

9. Reverse the previous procedures to install the newinjector(s) and reassemble.

IMPORTANT: The PTO Fuel Injector Harness wiresare Red/Black and White. The MAG Fuel InjectorHarness wires are Red/Black and White/Black.

10. Lubricate O-rings lightly with oil to aid installation. Torquethe fuel rail mounting screw to specification.

Fuel InjectorHarnesses

Disconnect Here

DO NOTDisconnect Here

FuelInjector

Harness

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Fuel Rail Mounting Screw16-20 ft. lbs. (22.6-27 Nm)

Fuel Injectors

Fuel RailMounting

Screw

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FUEL PUMPOperation OverviewAn electric fuel pump assembly is used to transfer fuel to the EFIsystem from inside the fuel tank. This assembly includes the fuelpump, fuel filters, regulator and fuel gauge sender. The pump israted for a minimum output of 25 liters per hour at 39 psi and hastwo non-serviceable fuel filters.

When the key switch is turned to "ON", the ECU activates thefuel pump, which pressurizes the system for start-up.

The ECU switches off the pump preventing the continueddelivery of fuel in these instances:

• If the key switch is not promptly turned to the "start" position.

• If the engine fails to start

• If the engine is stopped with the key switch "on" (as in the case of an accident).

In these situations, the “check engine” light will go on, but willturn off after 4 cranking revolutions if system function is OK.Once the engine is running, the fuel pump remains on.

Fuel Sender TestIf the fuel gauge reading on the instrument cluster is notworking, or if the display reading differs in large comparison tothe fuel in the tank, perform a resistance test on the fuel sender.

Disconnect the fuel pump / sending unit connection and measurethe resistance between the Purple and Brown wires (see chapter10 for further details). If out of specification, replace the fuelpump assembly.

Fuel Pump Assembly

Located in Fuel Tank

Fuel PumpRegulator

Pump / Sending Unit

Preliminary Filter

Fine Filter

Fuel LineConnection

Vent LineConnection

Connection

Fuel Sender Resistance Specifications:Full: 90 ± 4.5 ΩEmpty: 6 ± 1 Ω

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Fuel Pump TestIf a fuel delivery problem is suspected, make certain the fuelpump filters are not plugged, that the pump is being activatedthrough the ECU, all electrical connections are properlysecured, the fuses are good, and a minimum of 7.0 volts is beingsupplied. If during starting the battery voltage drops below 7.0volts, the ECU will fail to operate the system.

1. Remove the passenger seat from the vehicle.

2. Cover the fuel line connection at the fuel tank with a shoptowel and disconnect the fuel line from the fuel pumpoutlet.

3. Install the Fuel Pressure Gauge Adaptor (PV-48656) in-linebetween the fuel pump outlet and fuel line.

4. Connect the hose from the Fuel Pressure Gauge Kit (PU-43506-A) to the test valve on the Fuel Pressure GaugeAdaptor (PV-48656). Route the clear hose into a portablegasoline container or the vehicle’s fuel tank.

5. Turn on the key switch to activate the pump and check thesystem pressure on the gauge. If system pressure of 39 psi± 3 is observed, the ignition switch, ECU, fuel pump, andpressure regulator are working properly. Turn the keyswitch off and depress the valve button on the tester torelieve the system pressure.

NOTE: If the fuel pressure is out of specification,replace the fuel pump assembly.

6. If the pump did not activate (Step 3), disconnect the harnessconnector from the fuel pump. Connect a DC voltmeteracross terminals “A” and “C” in the plug on the vehicleharness side. Turn on the key switch and observe voltageto ensure a minimum of 7 volts is present.

NOTE: If the voltage was below 7 VDC, test thebattery, ignition switch, relay(s), wiring harness andECU.

7. If the reading is between 7 and 14 volts, turn key switch offand connect an ohmmeter between the terminals “A” and“C”' in the plug on the pump harness side to check forcontinuity within the fuel pump.

NOTE: If there was no continuity between the pumpterminals, replace the fuel pump assembly.

8. If voltage at the plug was within the specified range, andthere was continuity across the pump terminals, reconnectthe plug to the pump, making sure you have cleanconnections. Turn on the key switch and listen for the pumpto activate.

NOTE: If the pump starts, repeat steps 1, 2 and 3 toverify correct pressure.

9. If the pump still does not operate, check for correct ECUoperation by plugging in a known-good ECU of the samemodel.

NOTE: If the pump still does not operate, replace thefuel pump assembly.

WARNING

Fuel is extremely flammable and may cause severe burns, injury, or death.

Do not use any device that produces a flame or electrical devices that may spark around

fuel or fuel vapors.

Normal Fuel Pressure: 39 psi. ± 3

PV-48656

PU-43506-A

Disconnect and Test Here

Pin “A”Red

Pin “C”Brown

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Fuel Pump Replacement1. Remove the (6) mounting screws and carefully remove the

fuel pump from the tank. Take care not to damage the fuelsender float or fuel pick-up screen.

2. Replace O-ring on fuel pump assembly.

3. Clean the tank’s mating surface with Isopropyl Alcohol.

4. Carefully install the new fuel pump into the tank. Take carenot to damage the fuel sender float or fuel pick-up screen.

5. Install and hand tighten the mounting screws.

6. Torque screws to specification following the sequenceshow in the illustration below.

7. Apply the final torque using the same sequence.

Fuel Tank RemovalIMPORTANT: Syphon as much fuel from the tank aspossible before attempting to remove it from thevehicle.

1. Remove the driver and passenger seats along with the rearservice panel.

2. Disconnect the negative battery cable from the batterylocated under the driver’s seat.

3. While holding a shop towel over the fuel line connector,disconnect the quick connect fuel line from the fuel pump.

NOTE: A small amount of fuel may come out of thefuel line or tank. Properly drain fuel into a suitablecontainer.

4. Disconnect the fuel pump electrical harness.

WARNING

Never reuse the fuel pump O-ring.

= T

Fuel Pump Mounting Screws:Starting Sequence: 10-14 in. lbs. (1.1-1.6 Nm)

Final Sequence: 25-28 in. lbs. (2.8-3.2 Nm)

Remove (6)mounting Screws WARNING

Always wear safety goggles when working with high pressure or flammable fluids. Failure to do so

could result in serious injury or complications.

Disconnect Here

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5. Remove the fuel tank vent hose.

6. Remove the (2) push rivets from the rear of the centerconsole.

7. Remove the (2) fasteners from the rear seat base andremove the assembly from the vehicle.

8. Remove the (11) push rivets and (4) Torx screws retainingthe RH rocker panel and remove panel from the vehicle.

9. Remove the lower bolt retaining the seat belt mechanismnear the rear RH portion of the fuel tank. Once removed,place the mechanism in the rear cargo box to keep it out ofthe way.

10. Remove the (3) Torx fasteners from the rear RH fender welland remove the fender well from the vehicle.

NOTE: Lift fender well up over the fuel tank fillerneck and out from the vehicle.

RemoveRH Rocker Panel

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IMPORTANT: Take care not to place any excessiveforce on the filler neck

11. Remove the (2) tank bracket fasteners that retain the fueltank in the chassis.

12. Lift the rear of the fuel tank up first and carefully pull it outfrom the vehicle.

Fuel Tank Installation1. Carefully reinstall the fuel tank assembly.

2. Reinstall the (2) tank brackets and fasteners.

3. Reinstall the rear RH fender well and secure with fasteners.

4. Reinstall the seat belt mechanism and secure the lower bolt.

5. Reinstall the RH rocker panel and all (15) fasteners.

6. Reinstall the rear seat base and secure with the (2) fasteners.

7. Reinstall the push rivets into the rear of the center console.

8. Install the fuel line and vent hose and verify they are secure.

9. Reconnect the fuel pump electrical harness.

10. Reconnect the negative battery cable. Test the fuel pumpby turning on the key and listening for the pump to activate.

11. Finally, install the rear service panel along with the driverand passenger seats.

Tank BracketFasteners

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THROTTLE POSITION SENSOR (TPS)Operation OverviewThe throttle position sensor (TPS) is used to indicate throttleplate angle to the ECU. Mounted on the throttle body andoperated directly off the end of the throttle shaft, the TPS workslike a rheostat, varying the voltage signal to the ECU in directcorrelation to the angle of the throttle plate. This signal isprocessed by the ECU and compared to the internal pre-programmed “maps” to determine the required fuel and ignitionsettings for the amount of engine load.

TPS Learn Function (2010 Models)The TPS automatically learns the idle setting at every key-onoccurrence. This function provides more consistent calibrationby compensating for TPS drift. However, if the TPS reading getsbelow .690 Vdc or above .730 Vdc, the learn function is set todefault to the last successfully learned point and the “CheckEngine” or “MIL” indicator will illuminate. Performing the“TPS Adjustment” procedure will remedy this problem.

TPS Tester / RegulatorThe TPS reading can be checked by using the Throttle PositionSensor (TPS) Tester (2201519-A).

IMPORTANT: TPS Tester 2201519-A replaces theexisting TPS tester (PU-47082), which included the4010264 regulator. If your dealership has PU-47082and 4010264 you DO NOT need to order 2201519-A asa replacement.

Set-up the TPS Tester Wire Harness (PU-47466) and TPS TesterRegulator (547927) according to the instructions thataccompanied the tester. Make sure the 9 Volt battery is new.

The correct position of the throttle body stop screw is established and set at the factory.

DO NOT loosen the throttle body stop screw or alter its position in any manner. The stop screw controls the air flow calibration of the throttle body. If the

stop screw is repositioned or adjusted, the throttle body assembly must be replaced.

TPS Connector

Throttle Body

Stop Screw(Factory Set)

Yellow(Output)

Blue(Input)

Black(Ground)

TPS

DO NOT ADJUST

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Verify TPS Tester Reference Voltage

A 5 volt reference voltage from the TPS Tester harness isrequired for the TPS test to be accurate. Refer to the instructionsprovided with the TPS Tester (2201519-A) or follow the bulletpoint steps below to check reference voltage.

Reference Voltage Test:

• Insert black voltmeter probe into the test port as shown.

• Insert red voltmeter probe into the test port as shownand verify the voltage reads 4.99-5.01 Vdc. If thereading is low, replace the 9 volt battery.

IMPORTANT: Always use a fresh 9 Volt battery.

Checking TPS Reading1. Remove the driver and passenger seats along with the rear

service panel.

2. Remove the outlet duct from the PVT cover to access thethrottle body.

3. Loosen the hose clamps that secure the throttle body in theintake boot and intake adaptor. This will allow you to rotatethe throttle body to access the TPS or allow you to removethe throttle body to perform this procedure.

4. Assemble the TPS Tester according to the instructions.Refer to “TPS Tester / Regulator” for proper set-up andtesting. Verify the 9 volt tester battery is new.

5. Disconnect the vehicle chassis harness from the TPS.

NOTE: To allow better access to the TPS harnessconnection, remove the exhaust pipe and exhaustsilencer.

6. Plug the TPS Tester harness in the TPS harness.

7. Set your voltmeter to read DC Volts. Insert the red andblack voltmeter probes into the test ports as shown.

8. Move the throttle open and closed slowly while reading thedisplay. The voltage should increase and decreasesmoothly without any “jumps” when the throttle is applied.

9. If voltage varies with throttle movement, continue on toStep 10. If the sensor did not function correctly, replace it.

TPS Reference Voltage 5 Vdc Input

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10. Allow the throttle foot pedal to rest in the idle position. Thevoltmeter should read within the specification.

11. If the voltage does not read within the specification,proceed to the “TPS Adjustment” procedure. If the voltagereading is within specification, no adjustment is required.

TPS AdjustmentNOTE: This procedure should be performed afteryou have checked the TPS reading. Refer to“Checking TPS Reading” procedure before makingany adjustments.

1. Make sure the TPS Tester harness is still connected to theTPS harness.

2. Loosen the mounting screw (B) holding the TPS to thethrottle body (see Figure 4-29).

3. Rotate the TPS until your voltmeter reads withinspecification (see Figure 4-28).

4. Retighten the mounting screw, and verify the voltage didnot change. If the voltage changed, repeat steps 2 - 4.

5. Reconnect the TPS harness to the vehicle chassis harness.

TPS ReplacementNOTE: The correct position of the TPS angle on thethrottle body is established and set at the factory. Ifthe TPS is replaced, repositioned or loosened itmust be recalibrated. Refer to the “TPS Adjustment”procedure.

1. If the vehicle is completely assembled, remove the exhaustpipe and exhaust silencer from the vehicle to gain access tothe throttle body and TPS.

2. Disconnect the TPS harness connection (A).

3. Remove the mounting screw (B) and replace the sensor.

NOTE: If replacing the TPS or throttle body, youmust perform the “TPS Adjustment” procedure.

4. Refer to “TPS Adjustment” for setting the TPS voltage.

TPS Output Reading (2009 Models).730 ± .010 Vdc

TPS Output Reading (2010 Models).690 - .730 Vdc

Figure 4-28

TPSA

BFigure 4-29

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ENGINE COOLANT TEMPERATURE SENSOR (ECT)

Operation OverviewMounted on the cylinder head, the engine temperature sensormeasures coolant temperature. The engine temperature sensoris a Negative Temperature Coefficient (NTC) type sensor, as thetemperature increases the resistance decreases.

Coolant passes through the cylinder and by the sensor probe,varying a resistance reading which is relayed to the ECU. Thissignal is processed by the ECU and compared to itsprogramming for determining the fuel and ignitionrequirements during operation. The ECU also uses this signal todetermine when to activate the fan during operation. If for anyreason the engine temperature sensor circuit is interrupted, thefan will default to “ON”.

ECT Sensor TestTo quickly rule out other components and wiring related to theECT, disconnect the harness from the ECT. The fan should turnon. This indicates all other components are working properly.

Refer to Chapter 10 for ECT testing. Polaris dealers can also testthe sensor by using the Digital Wrench™ Diagnostic Software(dealer only). Refer to the Digital Wrench™ User Guide formore information.

ECT Sensor Replacement1. Drain coolant to level below sensor.

2. Disconnect sensor from engine harness.

3. Using a wrench, remove and replace the sensor, applyinga light coating of thread sealant to aid installation.

4. Torque the sensor to 17 ft. lbs. (23 Nm).

ECT

ECT Sensor Resistance Readings

Temperature °F (°C) Resistance

68 °F (20 °C) 2.5 kΩ ± 6%

212 °F (100 °C) 186 Ω ± 2%

= T

ECT Retaining Bolt Torque:17 ft. lbs. (23 Nm)

ECT Sensor

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IGNITION COILOperation OverviewThe ignition coil is used to provide high voltage to fire the sparkplugs. When the ignition key is on, DC voltage is present inprimary side of the ignition coil windings. During enginerotation, an AC pulse is created within the crankshaft positionsensor for each passing tooth on the flywheel. The two-toothgap creates an “interrupt” input signal, corresponding to specificcrankshaft position for PTO cylinder. This signal serves as areference for the control of ignition timing. The ECU thencalculates the time interval between the consecutive pulses, anddetermines when to trigger the voltage spike that induces thevoltage from the primary to the secondary coil windings to firethe spark plugs.

Ignition Coil TestsThe ignition coil can be tested by using an ohm meter. Use thefollowing illustration and specification table to test the ignitioncoil.

Primary Test

Secondary Test

Ignition Coil / HT Lead Replacement1. Remove the driver and passenger seats.

2. Remove the rear service panel to access the ignition coil.

3. Disconnect the ignition coil harness and remove the hightension leads from the coil.

4. Remove the fastener retaining the ignition coil and removethe coil from the vehicle. If replacing the high tensionlead(s), remove the other end of the lead(s) from the sparkplug.

5. Install the new ignition coil and/or high tension lead(s).

Ignition Coil Resistance Readings

Test Pin Connection Resistance

Primary Between 1 & 2 Between 3 & 2 0.4 Ω

SecondaryBetween High Tension Lead Ends

5 k Ω

Ignition Coil

= T

Ignition Coil Retaining Bolt Torque:75 in. lbs. (8.5 Nm)

Measure BetweenConnector Pins

0.4 Ω

Measure BetweenEnd Caps

5 k Ω

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GENERAL TROUBLESHOOTINGDiagnostic “Blink Codes”NOTE: The EFI diagnostic mode is intended toquickly view the cause of the “Check Engine” light.

To recall blink codes (fail codes) from the ECU:

1. Verify the key switch is off and the transmission is inneutral with the parking brake applied.

2. Turn the key switch ON and OFF 3 times within 5 secondsand leave the key switch in the ON position on the thirdturn. The word “Wait” will appear as the ECU searches forblink codes.

3. Any “blink codes” stored in the ECU will display anumerical “blink code”, one at a time, in numerical order,on the instrument cluster display.

4. The word “End” will display after all of the codes have beendisplayed or if no codes are present.

NOTE: To clear codes manually, disconnect thepositive battery lead for 20 seconds.

DIAGNOSTIC “BLINK CODES” CHART

P-Code Blink Code Name Check EngineP0335 21 Loss of Synchronization YesP0122 22 TPS: Open or Short Circuit to Ground YesP0123 22 TPS: Short Circuit to Battery YesP0601 23 RAM Error: Defective ECU YesP0914 25 Gear Sensor: Invalid Gear YesP0500 26 Vehicle Speed Sensor: Implausible YesP1121 27 TPS Set Error YesP0113 41 Intake Air Temp Sensor: Open or Short Circuit to +Sensor Voltage (ECU) YesP0112 41 Intake Air Temp Sensor: Short Circuit to Ground YesP0117 42 Engine Temperature Sensor Circuit: Short To Ground YesP0118 42 Engine Temperature Sensor Circuit: Open or Short to Battery YesP0107 45 Barometric Pressure Sensor: Circuit Low Input YesP0108 46 Barometric Pressure Sensor: Circuit High Input YesP1260 51 Injector 1: Open Load YesP0261 51 Injector 1: Short Circuit to Ground YesP0262 51 Injector 1: Short Circuit to Battery YesP1263 52 Injector 2: Open Load YesP0264 52 Injector 2: Short Circuit to Ground YesP0265 52 Injector 2: Short Circuit to Battery YesP0655 54 Engine Temperature Lamp: Open Load YesP1657 54 Engine Temperature Lamp: Short Circuit to Ground YesP1658 54 Engine Temperature Lamp: Short Circuit to Battery YesP1651 55 Diagnostic Lamp: Open Load YesP1652 55 Diagnostic Lamp: Short Circuit to Ground YesP1653 55 Diagnostic Lamp: Short Circuit To Battery YesP1231 56 Pump Relay: Open Load YesP1232 56 Pump Relay: Short Circuit to Ground YesP1233 56 Pump Relay: Short Circuit to Battery YesP1480 58 Cooling Fan Relay: Open Load YesP1481 58 Cooling Fan Relay: Short Circuit to Ground YesP1482 58 Cooling Fan Relay: Short Circuit to Battery Yes

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EFI Troubleshooting

Fuel Starvation / Lean Mixture

Symptoms: Hard start or no start, bog, backfire, poppingthrough intake / exhaust, hesitation, detonation, low power,spark plug erosion, engine runs hot, surging, high idle, idlespeed erratic.

• No fuel in tank

• Restricted tank vent, or routed improperly

• Fuel lines or fuel injectors restricted

• Fuel filter plugged

• Fuel pump inoperative

• Air leak in system

• Intake air leak (throttle shaft, intake ducts, airbox or air cleaner cover)

• Incorrect throttle stop screw adjustment

Rich Mixture

Symptoms: Fouls spark plugs, black, sooty exhaust smoke,rough idle, poor fuel economy, engine runs rough/ misses, poorperformance, bog, engine loads up, backfire.

• Air intake restricted (inspect intake duct)

• Air filter dirty/plugged

• Poor fuel quality (old fuel)

• Fouled spark plug

• TPS setting incorrect

• Injector failure

Poor Idle

Symptom: Idle Too High (If greater than 1300 RPM whenengine is warm)

• Throttle stop screw set incorrect

• Throttle cable sticking, improperly adjusted, routed incorrectly

Symptom: Idle Too Low (if less than 900 RPM when engine iswarm)

• Plugged air filter

• Leaking injector (rich condition)

• Belt dragging

• Throttle stop screw tampering

Symptom: Erratic Idle

• Throttle cable incorrectly adjusted

• Air Leaks, dirty injector

• TPS damaged or adjusted

• Tight valves

• Ignition timing incorrect

• Belt dragging

• Dirty air cleaner

• Engine worn

• Spark Plug fouled

• Throttle stop screw set incorrectly (out of sync with ECU)

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DIGITAL WRENCH™ OPERATIONDigital Wrench™ Diagnostic Software OverviewIMPORTANT: Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench™ DiagnosticKit 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

• Analyze real-time engine data

• Reflash ECU calibration files

• Perform guided diagnostic procedures

• Create customer service account records

• Perform output state control tests (on some models)

Special Tools (also refer to page 4.2)

Diagnostic Software VersionAlways 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 areadded to these updates as they become available. Forinformation on how to determine if you have the latest updateavailable, refer to “Digital Wrench™ Version and Update ID”.

ECU ReplacementAlthough the need for ECU replacement is unlikely, a specificreplacement procedure is required to ensure that all essentialdata contained within the original ECU is transferred to thereplacement ECU.

Refer to procedure and carefully follow all instructions providedin Digital Wrench™.

Guided Diagnostic AvailableGuided diagnostics are available within Digital Wrench™ forall supported Trouble Codes (that is, any fault that will turn onthe ‘Check Engine’ indicator).

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

Diagnostic procedures are added to subsequent versions ofDigital Wrench™ as they become available. Check your releaseversion often and upgrade when available to be sure you areusing the most current software available.

Digital Wrench™ Communication ErrorsIf you experience problems connecting to a vehicle or anyDigital Wrench™ related problem, visit the Digital Wrench™Knowledge Base for the most current troubleshootinginformation, FAQs, downloads and software updates at:http://polaris.diagsys.com/.

DIGITAL WRENCH™ DIAGNOSTIC SOFTWARE PART NUMBERDigital Wrench™ Diagnostic Kit PU-47063-A

PU-47063-A (listed above) INCLUDES:Digital Wrench™ Software: PU-48731Standard Interface Cable: PU-47151

SmartLink Module Kit: PU-47471Fuel Pressure Gauge Kit PU-43506-AFuel Pressure Gauge Adapter PV-48656Fluke 73 Digital Multi-Meter or Fluke 77 DMM PV-48656 (Fluke 77: PV-43568)Laptop or Desktop ComputerUSB/Serial Adaptor: Saelig RS-232

Commercially Available (refer to diagnostic software user manual or HELP section for minimum requirements)

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Digital Wrench™ - Diagnostic Connector

The diagnostic connector is located under the dash and isaccessible from the passenger side.

Follow these steps to connect the diagnostic interface cable tothe vehicle to allow Digital Wrench™ use:

1. Assemble the SmartLink Module and attach the PCInterface Cable to your laptop (see page 4.3).

2. Remove the protective cap from the Digital Wrench™connector.

3. Connect the Vehicle Interface Cable to the DigitalWrench™ diagnostic connector.

4. Turn the ignition key to the ‘ON’ position, select theappropriate vehicle and wait for the status to display‘Connected’ in the lower left corner of the screen.

5. Once connected, proceed with using Digital Wrench™.

Digital Wrench™ Serial Number LocationOpen the configuration screen by clicking on the wrench icon.The serial number is located on the right side of the screen.

Digital Wrench™ Version and Update IDKnowing what Digital Wrench™ version and update is installedwill help determine which updates are required.

NOTE: Versions and updates are subject to change.

1. Open the Digital Wrench™ software. Locate the versionID shown on the lower right side of the Digital Wrench™start-up screen.

2. In this case, the version number is 3.1 with a 03/13/09update. Proceed to http://polaris.diagsys.com to see if anewer update is available.

3. In this case, a newer update (04-27-09) is available andshould be downloaded before using Digital Wrench™ (see“Digital Wrench™ Updates”).

IMPORTANT: Always operate with the latest update.

Digital Wrench™ UpdatesUpdates are released for Digital Wrench™ via the Internet at:http://polaris.diagsys.com. The Digital Wrench™ website canalso be accessed through the dealer website at:www.polarisdealers.com.

NOTE: Only authorized Polaris dealers anddistributors can access the dealer website.

1. Log on to www.polarisdealers.com.

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

Version: 3.1 03/13/09

Digital Wrench Update 04-27-09

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3. Click on “Digital Wrench Updates”.

4. The Digital Wrench™ portal website should appear in anew web browser.

5. Click on “Digital Wrench Version 3.1 Updates”.

IMPORTANT: You must already have version 3.1installed before adding these updates. They will notinstall if you have version 3.0 or older on your PC.

6. If the update file date listed is newer than your currentversion and update (see “Digital Wrench™ Version andUpdate ID”), download the file.

7. Click on the link shown above, save the file to your harddisk and then double-click the icon to start the updateprocess.

NOTE: Do not "run" or "open" the file from wherethey are. Select "save" and download them to yourPC before running the install.

8. When the update is complete, the version shown on theright side of the Digital Wrench™ start-up screen shouldmatch the update you just downloaded.

NOTE: Versions and updates are subject to change.

Digital Wrench Update 04-27-09

Version: 3.1 04/27/09

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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 theDigital Wrench™ screen. Start Digital Wrench™ and click onthe Special Tests menu icon (red tool box). A technician shouldbe familiar with the process and with computer operation ingeneral before attempting to reprogram an ECU.

The Digital Wrench™ Engine Controller Reprogramming (or“Reflash”) feature allows reprogramming of the ECU fuel andignition map. To successfully reprogram the ECU, anAuthorization Key must be obtained by entering a Request Codein the box provided on the Reflash Authorization site. TheRequest Code is automatically generated by Digital Wrench™during the reprogramming process. The Reflash Authorizationsite is located under the “Service and Warranty” drop downmenu on the dealer website at: www.polarisdealers.com.

IMPORTANT: Failure to follow the reprogramminginstructions completely and correctly can result in anengine that does not run! Replacement ECUs areprogrammed as “no-start” and require a reflash forthem to work.

Reprogramming (Reflash) Tips:

• BATTERY VOLTAGE: The majority of problems withreprogramming can be attributed to a low battery. Besure the battery voltage (no load) is at least 13 volts andat least 12.5 volts with the key ‘ON’. Connect a batterycharger if necessary to bring voltage level aboveminimum. Fully charge the battery before you attemptto reprogram.

• DEDICATED LAPTOP: Best results are obtained usinga laptop computer that is “dedicated to DigitalWrench™”. A laptop that is used by a variety of peopleand in several applications around the dealership ismore likely to cause a reprogramming problem than onededicated to Digital Wrench™ diagnostics only.

• OBTAINING THE LATEST UPDATE:Reprogramming updates are provided periodically andcontain the most recent calibrations (see “DigitalWrench™ Updates”).

• CLOSE NON-ESSENTIAL PROGRAMS: Polarisrecommends that you DO NOT install non-essentialprograms on a Service Department laptop. Cameradetection software, Virus Scanners, Tool Bars, etc. mayclog up memory if running in the background and makeit harder for the diagnostic software to operate.

• KNOW THE PROCESS: If you are not familiar withthe entire reprogramming process, review the HELPsection of the diagnostic software before you attemptreprogramming. Click on the ? on the tool bar or pressF11. The information in the on-line help is the mostcurrent and complete information available. Thisshould be your first step until you are familiar with theprocess.

• COMMUNICATION PROBLEMS: If you have hadproblems communicating with a vehicle whileperforming diagnostic functions, do not attemptreprogramming until the cause has been identified andfixed. Check all connections, and be sure batteryvoltage is as specified.

Proceed to http://polaris.diagsys.com for specificinformation and FAQs on how to troubleshootcommunication problems.

• DON’T DISTURB THE PC: While reprogramming isin progress, don’t move the mouse and don’t touch thekeyboard. The process only takes a few minutes, and isbest left alone until complete.

Reprogramming (Reflash) Procedure:

If you are not familiar with the reprogramming process, reviewthe “Reprogramming (Reflash) Tips” before you begin. Followthe on-screen instructions as you progress through the steps. Ifyou encounter a problem, always check the On-Line help forcurrent tips and information.

1. Verify the most current update has been downloaded andloaded into Digital Wrench™. See “Digital Wrench™Version and Update ID” on page 4.33.

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2. Connect the SmartLink Module cables to the PC andvehicle. See “Digital Wrench™ - Diagnostic Connector”on page 4.33.

3. Open the Digital Wrench™ program.

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

5. Select the “Special Tests” icon.

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.

8. Follow the on screen instructions and connect a 9V batteryto the reflash battery connector located off the maindiagnostic connector. Click the “Continue” icon to obtaina Request Code.

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9. Copy (CTRL+C) the Request Code that will be required onthe dealer website in the next step. DO NOT CLOSEDigital Wrench™ or the Request Code will be invalid.NOTE: All characters are letters; there are no numbersin a request code.

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

10. Go to www.polarisdealers.com and click on “ReFlashAuthorization” from the “Service and Warranty” drop-down menu.

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

12. Select the same file type from the list that you selectedpreviously while in Digital Wrench™. Enter the VIN alongwith the customer’s name and address. When completed,click the Authorize button once to proceed.

13. An “Authorization Key” will appear in the upper left cornerof the screen. Copy (CTRL+C) this key exactly as itappears.

14. Enter or paste (CTRL+C) the Authorization Key in the boxlocated on the Digital Wrench™ screen. Click the‘Continue’ button and follow instructions provided on thescreen to complete the reprogramming procedure.

Copy Request Code toobtain Authorization Key

Authorization Key goes here afterobtained from the dealer website

“Reflash Authorization”“Service and Warranty”

Enter the“Request Code”

Enter ALL the information andclick on the “Authorize” button

“Authorization Key”

Enter the“Authorization Key”

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15. At this point the reflash process will begin. Do not touchthe vehicle or PC during the process.

16. Once the ECU reprogramming procedure is complete, clickthe ‘Finish’ button on the screen. Verify the reflash was asuccess by starting the vehicle.

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