Snowmobile Polaris Two Stroke (2007 year). Manual - part 77

11.45

BATTERY & ELECTRICAL SYSTEMS

11

Version / Fileset Identification

Knowing what Digital Wrench or fileset versions are installed
will help determine which updates are required.

NOTE: Version and fileset versions are subject to
change.

1.

Start the Digital Wrench software.

2.

Locate the version ID on the title screen.

3.

Click on the “SPECIAL TESTS” icon (toolbox).

4.

Click on “ENGINE CONTROLLER
REPROGRAMMING”.

5.

Locate the fileset version number.

Engine Controller Reprogramming (Reflash)

NOTE: 

New service replacement ECUs are

programmed as “no-start” and require a reflash in
able to work.

1.

Verify the most current service packs, updates and filesets
are downloaded and loaded into Digital Wrench. See
“Version / Fileset Identification” on page 11.45.

2.

Connect the communication cables to the snowmobile
connectors. See “Digital Wrench Connections” on
page 11.43.

3.

Start Digital Wrench. Select the model year and machine
using the “CHANGE VEHICLE TYPE” button.

4.

Click on the “SPECIAL TESTS” icon.

5.

Click on “ENGINE CONTROLLER
REPROGRAMMING”.

6.

Select the engine model and color of the injectors installed
on the engine.Record the 7 digit injector part number. Click
“CONTINUE”.

NOTE:  Remember, all four fuel injectors must share
the same color code.

7.

Locate the “program enable” or “mode change 2 (callout on
schematic)” jumper connector. Jump the two pins using a
short length of wire. Click “CONTINUE”.

CAUTION

Do not allow the jumper wire to touch the exhaust pipe 
or any other grounded metal. ECU damage may occur.

PROGRAM ENABLE 

JUMPER

(BLACK TWO-PIN PLUG)

11.46

BATTERY & ELECTRICAL SYSTEMS

8.

A request code will be generated. Record the code.

9.

Access www.polarisdealers.com. Locate “REFLASH
AUTHORIZATION” under the “SERVICE AND
WARRANTY” drop-down menu.

10. Locate and click on the product requiring the reflash. Click

on the model year.

11. Enter the request code generated by Digital Wrench. Select

the fuel injector color and model year/engine from the drop-
down menu.

12. The website will generate an authorization code. Record the

code.

13. Enter the authorization number in the box on Digital

Wrench. Click on “CONTINUE”.

14. The reflash process will begin. Verify all connections are

properly made. Do not touch anything during the process.

15. Verify the reflash was a success by comparing the software

ID number listed under the “CUSTOMER AND VEHICLE
IDENTIFICATION” button with the number recorded in
step 6.

11.47

BATTERY & ELECTRICAL SYSTEMS

11

CARBURETED ELECTRICAL 
SYSTEMS

EC50PL Stator Specifications

NOTE: Use a multimeter to test the stator circuits.
Remember to test the circuits when the engine is
cold and after the engine has been running for some
time.

EC34 / EC55 Stator Specifications

NOTE: Use a multimeter to test the stator circuits.
Remember to test the circuits when the engine is
cold and after the engine has been running for some
time.

500cc EV / 600 HO Stator Specifications

NOTE: Use a multimeter to test the stator circuits.
Remember to test the circuits when the engine is
cold and after the engine has been running for some
time.

Ignition Coil Packs

NOTE: Specifications listed for all models except
EC50PL (488cc) as this model features a CDI / coil
pack.

Exhaust Valve Solenoid

Knock Sensor

Specifications 

BRN / WHT TO BLK / RED

164 

Ω

YELLOW TO YEL / RED

0.2 - 0.5

Ω

YEL / RED, WHT, BRN TO GROUND

0

Ω

Specifications

YEL TO BRN

0.16

Ω

BRN TO ENGINE

0

Ω

BLK / RED TO GRN

13

Ω

RED TO GRN

13

Ω

RED TO ENGINE

OPEN

Ω

BLK TO ENGINE

0

Ω

WHT / RED TO WHT

185

Ω

WHT TO ENGINE

OPEN

Ω

Specifications

YEL TO BRN

0.15

Ω

BRN TO ENGINE

0

Ω

BLK / RED TO GRN

15

Ω

RED TO GRN

15

Ω

BLK or WHT TO ENGINE

0

Ω

WHT / RED TO WHT

185

Ω

Specifications

BLK TO WHT (Primary)

0.3

Ω

BLK or WHT TO SECONDARY LEAD

OPEN

Ω

SECONDARY LEAD TO LEAD

5K

Ω

PLUG CAPS

10K

Ω

Specifications

Coil Resistance
(WHT/YEL to RED)

15

Ω +/- 15% @ 68°F (20°C)

11.48

BATTERY & ELECTRICAL SYSTEMS

600HO Coolant Temperature Sensor

500 EV Coolant Temperature Sensor

Oil Level Sender

To test the oil level sender, position the sender as it would be in
the oil tank. Allow the float to drop in the direction it would if
the oil tank were empty. Continuity should be present when
using a multimeter to test the sender with the float in the “empty”
position. 

No continuity should be present when the float is moved away
from the “empty” position.

600 HO Regulator / Rectifier

Sensor Specifications

Operating Temperature Range

-22_F - +248 _F (-30_C - 120_C)

Resistance

2.4 - 2.6K

Ω@ 68_F (20_C)

(Measure in stirred water)

Installation Torque

29 ft.lbs. (39.2Nm)

Sensor Specifications

Temperature (F / C)

Resistance (OHMS)

-22_F / -30_C

22914 - 28006

Ω

32_F / 0_C

5085 - 6215

Ω

68_F / 20_C

2189 - 2675

Ω

149_F / 6_C

455 - 556.2

Ω

221_F / 105_C

152.8 - 186.8

Ω

Circuit Specifications

PLUG / PIN / COLOR

FUNCTION

STATOR / 2 / BROWN

GROUND

STATOR / 3 / YELLOW

AC POWER INPUT

STATOR / 4 / BROWN

GROUND

STATOR / 6 / YELLOW

AC POWER INPUT

HARNESS / A / YELLOW

REGULATED AC POWER

HARNESS / B / ORG/BLK

DC BRAKE LAMP GROUND

HARNESS / C / ORANGE

AC BRAKE SIGNAL INPUT

HARNESS / D / BRN/WHT

DC GROUND

HARNESS / F / BROWN

AC GROUND

HARNESS / G / YELLOW

REGULATED AC POWER

HARNESS / J / RED/WHT

REGULATED DC MFD POWER

HARNESS / K / RED

REGULATED DC BATTERY POWER

HARNESS / M / BROWN

AC GROUND

METAL TAB

GROUND PLATE