Snowmobile Polaris Two Stroke (2007 year). Manual - part 78

11.49

BATTERY & ELECTRICAL SYSTEMS

TROUBLESHOOTING TABLES

NO SPARK

No Spark Condition

Disconnect the single black (black/white) wire from the CDI Module to the
ignition kill circuit. Does it have a spark?

Check the ignition switch, wire harness, throttle safety switches and kill
switch for proper adjustment or short to ground. Repair or replace as
necessary.

YES

Disconnect the stator to CDI module wires. Test the resistance values of the
stator coils as per the wiring diagrams. Are the resistance values within
specs?

If the parts of the ignition system under the flywheel check OK, the only
remaining component is the coil/CDI module assembly. Replace the module
with another with the same number.

YES

Isolate which component's resistance is not within specs. Remove the
flywheel and stator. Recheck the resistances; look for pinched or bare
harness wires; or replace the coil.

Incorrect Timing (Advanced/Retard)

Follow the engine timing procedure for checking running timing at
recommended RPM. Is the timing within limits?

Adjust the ignition timing by rotating the stator plate to correct the timing. After
adjusting the recommended RPM timing, continue with operating RPM timing
if poor performance exists. (Continue on with left column.)

YES

Remove the ignition kill circuit by disconnecting the single black wire between
the CDI module and the machine harness. Is the timing now correct?

Check the ignition switch, throttle safety switches, kill switch and harness for
damage which can cause intermittent shorting problems. Correct the
problem.

YES

Verify the correct CDI module by comparing the CU code on the box to the
information listed in the ignition data charts at the beginning of this section.
Is it the right module?

Replace the module with the correct part and readjust the ignition timing.

YES

Check the resistance of the coils under the flywheel. Compare these to
values on wiring diagram. Are they within limits?

Check the wiring connecting the coils and/or replace the coils as necessary.

11.50

BATTERY & ELECTRICAL SYSTEMS

DETONATION CONTROL (DET)

Overview

Detonation control is achieved by using a knock sensor mounted
to the cylinder head and an ECU (CFI engines) or the CDI
(600HO engines).

The knock sensor “listens” for combustion knock by converting
internal engine noise in to an electrical signal. The ECU or CDI
uses the signal to determine the level of knock within the
combustion chambers after each combustion event.

When the ECU or CDI determines detonation has occurred, the
CHECK ENGINE / DET LED lamp will blink on and off at 0.5
second intervals.

On CFI models, the ECU will retard timing and provide
additional fuel to eliminate the detonation. On carbureted
engines, the CDI will retard timing until the detonation stops. If
the detonation continues past a pre-determined level, the ECU
or CDI will initiate an engine mis-fire mode.

To prevent detonation, follow these steps:

• Always use premium fuel (91, 92, or 93 octane)

• On carbureted engines, follow the carburetor jetting

guidelines

• Do not modify the engine or exhaust system with non-

approved Polaris modifications

• Verify there is no water or foreign material in the fuel

• Verify there is no internal engine damage

• Verify the cooling system is working properly

NOTE: Install the knock sensor fastener clean and
dry without applying thread locker or oils.

VARIABLE EXHAUST SYSTEM (VES)

Overview

The Polaris VES system uses exhaust valves (1 per cylinder) to
control the exhaust port height. The valves are actuated by
controlling cylinder pressure with a solenoid, bellows, and a
series of hoses.

At idle speed and up to a pre-determined level, the solenoid is
powered by the ECU or CDI. This action opens the solenoid’s
internal valve and allows the cylinder pressure to vent into the
atmosphere. During this time the valves are down.

In order to raise the valves, the ECU or CDI will cut power to
the solenoid which will close the vent path to atmosphere. The
cylinder pressure will then act upon each valve bellows which
will raise each valve.

On CFI engines the timing at which the solenoid is turned off is
determined by engine RPM, TPS position, and pipe
temperature. On carbureted engines, the CDI will turn the
solenoid off at 6700 RPM when the throttle flipper is at least
3/4 throttle or at 7200 RPM when the throttle flipper is at least
1/2 throttle.

NOTE: Solenoid Powered = Vent Path Open

Solenoid De-Powered = Vent Path Closed

11.51

BATTERY & ELECTRICAL SYSTEMS

DIAGNOSTIC PLUGS

IQ Chassis Power Plug

IQ models (CFI and carbureted) feature a chassis power
diagnostic plug. Connect the plug to the M-10 ACE / ECU-
Chassis Power-Up cable, PN PA-46355 and a fully charged 12-
volt battery. The plug consists of two wires (BRN and RED/
WHT).

Once powered, all of the RED/WHT chassis power circuits will
be powered with battery voltage. The circuits include:

• Head / Tail / Brake Lamps

• MFD (Multi Function Display)

• Accessory Power Plugs

• Hand / Thumb Warmers

IQ CFI Fuel Pump Prime Plug

IQ CFI models feature a fuel pump prime plug. Use the fuel
pump prime plug to power-up the fuel pump when purging the
fuel system of air or when testing fuel pump pressure.

The fuel pump prime plug consists of two wires (BRN and
RED).

ELECTRONIC REVERSE (PERC)

Overview

Some models are equipped with Polaris electric reverse control
(PERC). The operation of the electronic reverse system is
achieved by automatically reversing the engine rotation with a
push of a button. When in reverse you will have an indicator
light that will flash, notifying you that the machine is in the
reverse mode. The design of the clutches are matched to the
specifications that will allow the backwards rotation of the
engine to move the sled in reverse. To get back to forward is as
easy as pushing the button again.

Operation

Ensure that the vehicle is stopped and the engine is
warmed up and running at idle.

NOTE: The system will only engage in reverse if the
engine is below 4000 RPM. If engine is above 4000
RPM the system can not be activated.

Ensure that the path behind you is clear.

Push and hold the yellow reverse button on the left hand
control for 1 second and then release the button. The reverse
light on the instrument panel will flash when engine is in
reverse motion.

NOTE: The engine will automatically reduce RPM
and it will reverse the rotation of the engine when the
RPM is at the lowest RPM point.

Ensure that the path behind you is clear.

Slowly apply throttle until the sled starts to move in reverse,
and carefully direct the sled in the direction that you want.

NOTE: Maximum RPM in reverse is 6000 RPM.

FUEL PUMP

PRIME PLUG

CHASSIS POWER-UP

(2- WIRE CONNECTOR)

WARNING

Reverse operation, even at low speeds, may cause
loss of control, resulting in serious injury or death. To
avoid loss of control, always:
LOOK BEHIND BEFORE AND WHILE BACKING.
AVOID SHARP TURNS.
SHIFT TO OR FROM REVERSE ONLY WHEN
STOPPED.
APPLY THROTLE SLOWLY.

CAUTION

To avoid personal injury and/or engine damage, do not
operate the electric start or recoil while engine is
running.

11.52

BATTERY & ELECTRICAL SYSTEMS

NOTE: If the engine stops running or is shut off
while in reverse. The engine will start in forward
gear.

FORWARD OPERATION

If unit was operated in reverse, ensure that the path ahead
is clear, and push an hold the reverse button for 1 second
and then release the button. The engine will now
automatically change direction form reverse to forward
and the reverse light on the instrument panel will stop
flashing.

NOTE: When servicing clutches, ensure that the
vehicle is in forward gear. If not damage to the
driven clutch may occur when removing the belt.

Altitude Setting

If your engine is carbureted, you can adjust the elevation setting
of the Polaris electric reverse control (PERC). If your engine is
a Cleanfire system, this is automatically done through the
engine controller unit (ECU), and you do not need to do any
setting.

At higher elevations over 6000 ft (1829m), the engine requires
a different ignition RPM setting to improve the operation of the
reverse system.

To set the altitude settings:

With the engine running, push and hold the reverse button
for 5 - 6 seconds and then release the button.

The reverse light will flash rapidly on the instrument panel.

You have now set the PERC system to the higher elevation
setting.

To go back to the low elevation setting repeat step 1. The
reverse light will flash slowly indicating that the system is
now in the lower elevation setting.

NOTE: The elevation setting will be set in the
memory (engine running or not) until it is changed.

Important Notes

• Max RPM for shifting into reverse = 4000 RPM

• Max RPM for operating in reverse = 6000 RPM

• Engine must first reach 900 RPM at start up before the

reverse system can be used. The system works between
900 and 4000 RPM.

• If the button is pushed above 4000 RPM the system is

bypassed and nothing will happen.

• Flashing light on the instrument panel indicates that the

system is in reverse. On carbureted units a slow flash
indicates that the system is set for low elevation, and a

fast flash indicates the system is set up for high
elevation. Push and hold the reverse button for longer
than 5 seconds to toggle back and forth from high and
low elevation settings. On Cleanfire units this is
automatically done through the engine controller unit
(ECU).

• Elevation above 6000 ft (1829m) requires a different

timing curve to eliminate a “kick-back” effect.

• If engine is shut off or dies in forward or reverse gear,

the engine when started will automatically be in
forward gear.

• When servicing clutches, ensure that the vehicle is in

the forward gear.

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