Snowmobile Polaris (2006 year). Manual - part 67

13.10

ELECTRICAL

EXAMPLE: Short meter leads together, meter reads 0.7 ohms. 
Measure stator resistance, meter reads 1.10 ohms. Subtract 0.7 
ohms (meter/lead resistance) from 1.10 ohms (reading 
obtained when checking yellow lead to brown lead). True 
reading is:1.10 ohms (observed reading when checking stator) 
-.7ohms (meter/lead resistance) = 0.4 ohms (true stator 
resistance).

2.

Turn the multitester dial to the Volts AC (V~) position.

3.

Disconnect the alternator to main harness connector at
engine.

4.

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.

5.

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. 

REGULATED VOLTAGE

1.

Connect the alternator to main harness connector.

2.

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

3.

Ground the other tester lead.

4.

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.

5.

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.

6.

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.

SHORT CIRCUIT CURRENT (AC Amp Test)

1.

Turn multitester dial to A~.

2.

Connect red lead to 10A terminal.

3.

Connect black lead to Com (-) meter terminal.

4.

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

5.

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

page 13.2. 

CAUTION: Can blow

meter fuse if used on big alternators.

ALTERNATORS

The difference between a 2 pulse and 6 pulse alternator 
system is the number of AC sine waves created by the 
alternator in one revolution of the crankshaft. For example, on 
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. Refer to the following for 
applications.

500 Classic = 2 pulse

CAUTION

Can blow meter fuse if used on big alternators.

13.11

ELECTRICAL

340, 550, 600 Classics = 6 pulse

ELECTRICAL TESTING

HEADLIGHT BULB FILIMENT CONTINUITY 
TEST

1.

Turn the Multitester dial to the ohms () position.

2.

Disconnect the wire harness from the headlight bulb.

3.

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.

4.

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 / LOW BEAM SWITCH TESTING

1.

Set the multitester dial to the ohms (

Ω

) position.

2.

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

3.

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.

4.

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

5.

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

6.

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

SEAT HARNESS TROUBLESHOOTING

1.

Remove the taillight lens.

2.

Remove the two taillight bulbs and the brake light bulb.

3.

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

4.

With the multitester dial set on ohms (

Ω

) connect either

meter test lead to the brown seat harness wire.

5.

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.

6.

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.

7.

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

8.

Reinstall the staples and re-check the seat harness.

IGNITION SWITCH TESTING (NON-
ELECTRIC START)

1.

Set the multitester dial to the ohms (

Ω

) position. Connect

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

2.

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

3.

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.

13.12

ELECTRICAL

IGNITION SWITCH TESTING (ELECTRIC 
START MODELS)

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

1.

Disconnect wires. Set the multitester dial to the ohms 

Ω

position.

2.

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. 

3.

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

4.

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). 

5.

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.

6.

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.

500/600 TEMPERATURE LIGHT

Models with TPS are fitted with a thermistor sensor. This 
sensor outputs a variable resistance with temperature. This 
allows more capability for control when the over heat 
indicator light illuminates. Higher throttle positions require 
lower temperature for the light to come on, possibly leading 
the operator to believe it to be a blinking light.

For example, the TEMP light will come on at idle (under 2000 
RPM, 0% throttle) if coolant temperature reaches 230

_

F 

(110

_

C). Timing retard initiates at 176

_

F if the TPS input is 

over 80-100%. For more severe conditions, the engine fail-
safe is turned on at high TPS input and high temperatures.

At room temperature 68

_

 F (20

_

 C) the thermistor should read 

2189 to 2675 ohms. See chart below for other temperature 
resistances.

SPEED CONTROL ASSURANCE SWITCH

The speed control assurance consists of two series connected 
switches. If one or both switch plungers are positioned 
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 SWITCH 
ADJUSTMENT

Throttle 
lever free 
play must 
always 
provide a 
specified 
clearance 
between 
throttle 
lever and 
throttle 
block. 
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 

CAUTION

I

F

 

ATTEMPTING

 

TO

 

HEAT

 

THE

 

SENSOR

, 

HEAT

 

ONLY

 

IN

 

A

 

WATER

 

BATH

. N

EVER

 

SUBJECT

 

THE

 

SENSOR

 

TO

 

AN

 

OPEN

 

FLAME

 

TO

 

ATTEMPT

 

TO

 

CLOSE

 

THE

 

CONTACTS

 

AS

 

SENSOR

 

DAMAGE

 

MAY

 

RESULT

.

Table 13-5: Temp and Ohms Resistance 

Range

TEMP _F (_C)

OHMS 

Ω 

RESISTANCE 

RANGE

68 (20)

2189 - 2675

149 (65)

455 - 556

203 (95)

197 - 270

239 (115)

120 - 147

275 (135)

77 - 94

13.13

ELECTRICAL

throttle lever to throttle block clearance, the engine may 
misfire or kill upon initial throttle opening.

NOTE:  When adjustments are made on models 
which have more than one carburetor, refer to 
Carburetion chapter, for proper carburetor 
synchronization adjustments.

AUXILIARY SHUT-OFF SWITCH TESTING

1.

Set the multitester in the ohms (

Ω) position.

2.

Disconnect the switch harness from the main wire harness.

3.

Connect the two multitester leads to the two switch wires.

TEST 1 - OPEN CIRCUIT (RUN)

With the auxiliary shut-off switch in the ON position, the 
multitester should read an open circuit (OL). As the throttle 
lever is moved from idle to off idle, the tester should continue 
to read an open circuit. If the tester fluctuates and the throttle 
lever to throttle block clearance is adjusted properly, the 
switch assembly must be replaced.

TEST 2 - CLOSED CIRCUIT (OFF)

The two speed control switches must make a complete circuit 
to kill the engine. To check the switches, pull the throttle lever 
out away from the throttle block. With the switch plungers 
outward and the auxiliary shut-off switch in the ON position, 
the multitester must read less than.4 ohms resistance. Inspect 
wires and repair if damaged, or replace switch assembly.

TEST 3 - AUXILIARY SHUT-OFF

The multitester should read less than.4 ohms in the OFF 
position and an open circuit in the ON position. Inspect wires 
and repair if damaged, or replace switch assembly.

FUEL SENDER TESTING

Use the multitester ohmmeter to test the resistance of the fuel 
sender.

CAUTION

A

FTER

 

ANY

 

IDLE

 

SPEED

 

ADJUSTMENTS

 

ARE

 

MADE

, 

THE

 

THROTTLE

 

LEVER

 

TO

 

THROTTLE

 

BLOCK

 

CLEARANCE

 

AND

 

OIL

 

PUMP

 

ADJUSTMENT

 

MUST

 

BE

 

CHECKED

 

AND

 

ADJUSTED

.

Table 13-6: Fuel Sender Testing Range

POSITION

OHMS 

Ω

OHMS 

RANGE

EMPTY

95

Ω

90 - 97.5

Ω

FULL

7

Ω

4.5 - 13

Ω