2011-2012 RANGER 800 XP / HD / CREW / 6x6 Chapter 10 .

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ELECTRICALCHAPTER 10ELECTRICALGENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3SPECIAL TOOLS / ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3COMPONENTS UNDER HOOD / BEHIND DASH PANEL . . . . . . . . . . . . . . . . . . . . . . 10.3SWITCHES / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4HEADLAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4IGNITION KEY SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5AWD / 2WD / TURF SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5PARKING BRAKE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.62011 / 2012 TRANSMISSION (GEAR POSITION) SWITCH . . . . . . . . . . . . . . . . . . . . . 10.7VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8SPEED SENSOR LOCATION / TESTING (4X4 MODELS) . . . . . . . . . . . . . . . . . . . . . . 10.8SPEED SENSOR LOCATION / TESTING (6X6 MODELS) . . . . . . . . . . . . . . . . . . . . . . 10.8REAR DIFFERENTIAL SOLENOID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9DIFFERENTIAL SOLENOID OVERVIEW / CIRCUIT OPERATION. . . . . . . . . . . . . . . . 10.9INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11INFORMATION DISPLAY AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14INSTRUMENT CLUSTER PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15INSTRUMENT CLUSTER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 10.16ALL WHEEL DRIVE COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17HEADLIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18HEADLIGHT HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18HEADLIGHT HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19TAIL LIGHT / BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20LED LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21COOLING SYSTEM BREAK-OUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21FAN CONTROL CIRCUIT OPERATION / TESTING / BYPASS TEST . . . . . . . . . . . . 10.22COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22EFI DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22FUEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22FUSE BOX: FUSES / RELAYS / CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . 10.23OVERVIEW / OPERATION (MODEL YEAR 2011) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23OVERVIEW / OPERATION (MODEL YEAR 2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24FUSE BOX DETAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25RELAY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28CHARGING SYSTEM ALTERNATOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.28REGULATOR / RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29CHARGING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.301010.19923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ELECTRICALBATTERY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31BATTERY TERMINALS / BOLTS / TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . 10.31BATTERY ACTIVATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31BATTERY INSPECTION / REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 10.32CONVENTIONAL BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33OCV - OPEN CIRCUIT VOLTAGE TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33SPECIFIC GRAVITY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34BATTERY CONDUCTANCE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.34STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35STARTER MOTOR REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.35BRUSH INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.36ARMATURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37STARTER REASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.37STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.38STARTER SOLENOID BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39STARTER SOLENOID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.39STARTER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.40STARTING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.41ELECTRONIC POWER STEERING (EPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.42EPS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.42PROPER EPS SYSTEM DIAGNOSING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.42EPS SYSTEM BREAKOUT (MODEL YEAR 2011) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.43EPS SYSTEM BREAKOUT (MODEL YEAR 2012) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.44EPS TROUBLESHOOTING (EPS NON-FUNCTIONAL WITH MIL ON) . . . . . . . . . . . 10.45EPS TROUBLESHOOTING (EPS NON-FUNCTIONAL WITH MIL OFF) . . . . . . . . . . 10.46EPS TROUBLESHOOTING (USING DIGITAL WRENCH ). . . . . . . . . . . . . . . . . . . . 10.47ELECTRICAL SYSTEM BREAKOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48CHARGING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.48CONSTANT BATTERY POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.49KEY-ON BATTERY POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.50ELECTRONIC POWER STEERING (EPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.51ENGINE START (STARTER INTERLOCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.52AWD / TURF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.53VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.54ECM WAKE-UP / FUEL PUMP AND LEVEL / IGNITION COIL . . . . . . . . . . . . . . . . . . 10.55LIGHTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5610.29923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ELECTRICALGENERAL INFORMATIONComponents Under HoodSpecial ToolsThe following components can be accessed under thehood.Part NumberTool Description Voltage Regulator (in front of radiator)PV-43568Fluke 77 Digital Multimeter BatteryPV-43526Connector Test Kit Battery Cables2870630Timing Light Terminal BlockBattery Hydrometer Starter Solenoid2460761Hall Sensor Probe Harness Relays2871745Static Timing Light Harness FusesPU-47063Digital Wrench Diagnostic Software Digital Wrench Diagnostic ConnectorPU-47471Digital Wrench SmartLink Module KitPU-50338SPX Corp: 1-800-328-6657 or http://polaris.spx.com/Components Behind Dash PanelThe following components can be accessed with the dashpanel removed (see Chapter 5 for removal).Electrical Service NotesKeep the following notes in mind when diagnosing anelectrical problem: Instrument Cluster (Speedometer) AWD/2WD/TURF Switch Refer to wiring diagram for stator and electricalcomponent resistance specifications. Headlight Switch When measuring resistance of a component thathas a resistance value under 10 Ohms, rememberto subtract meter lead resistance from the reading.Connect the leads together and record theresistance. The resistance of the component isequal to tested value minus the lead resistance. Ignition Switch 12 VDC Accessory Power Points Parking Brake Switch Become familiar with the operation of your meter.Be sure leads are in the proper jack for the testbeing performed (i.e. 10A jack for currentreadings). Refer to the Owner’s Manual includedwith your meter for more information. Voltage, amperage, and resistance valuesincluded in this manual are obtained with aFluke 77 Digital Multimeter (PV-43568). Thismeter is used when diagnosing electricalproblems. Readings obtained with other metersmay differ.10 Pay attention to the prefix on the multimeterreading (K, M, etc.) and the position of the decimalpoint. For resistance readings, isolate the component tobe tested. Disconnect it from the wiring harness orpower supply.10.39923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ELECTRICALSWITCHES / CONTROLSHeadlamp SwitchBrake Light Switch1. Disconnect the headlamp switch harness bydepressing the connector locks and pulling on theconnector. Do not pull on the wiring.The brake light switch is located on the master cylinderbehind the front left wheel well panel.1. Remove the front left wheel well panel to access theback side of the master cylinder.2. Disconnect the wire harness from the brake switch.2. Test between the 3 sets of outputs (HIGH / LOW /OFF). If any of the tests fail, replace headlamp switchassembly. Move the switch to HIGH. There should becontinuity between switch pins 2 and 3; 5 and 6. Move the switch to LOW. There should becontinuity between switch pins 2 and 3; 4 and 5.Brake Switch Move the switch to OFF. There should becontinuity between switch pins 1 and 2.3. Connect an ohmmeter across switch contacts.Reading should be infinite (OL).4. Apply foot brake and check for continuity betweenswitch contacts. If there is no continuity or if resistanceis greater than 0.5 ohms, clean the switch contactsand re-test. Replace switch if necessary.NOTE: Pins 7 and 8 provide power and ground tolight the switch lamp.10.49923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ELECTRICALIgnition Key SwitchAWD / 2WD / TURF Switch1. Disconnect the key switch harness by lifting theconnector lock and pulling on the connector. Do notpull on the wiring.1. Disconnect the AWD / 2WD / TURF switch harnessby depressing the connector locks and pulling on theconnector. Do not pull on the wiring.2. Test between the 3 sets of outputs (OFF / ON /START). If any of the tests fail, replace ignition switchassembly.2. Test between the 3 sets of outputs (AWD / 2WD /TURF). If any of the tests fail, replace the switchassembly. Turn the ignition key to ON. There should becontinuity between switch pins C and D. Move the switch to AWD. There should becontinuity between switch pins 2 and 3; 5 and 6. Turn the ignition key to START. There should becontinuity between switch pins A and B; C and D. Move the switch to 2WD. There should be nocontinuity between any pins. Move the switch to TURF. There should becontinuity between switch pins 1 and 2; 4 and 5.NOTE: Pins 7 and 8 provide power and ground tolight the switch lamp.1010.59923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ELECTRICALParking Brake SwitchTesting The Parking Brake SwitchThe parking brake switch is located within the parkingbrake lever. Follow the parking brake lever under the dashto locate the internally mounted switch.1. Disconnect the harness connector at the parkingbrake switch (Orange/Red and Red/Yellow wires).2. Place the ohmmeter leads onto the switch terminals.The reading should be infinite (OL).3. Apply the parking brake. Continuity should now existbetween the switch terminals. If no continuity existswhen the parking brake is applied, try to clean theswitch terminals and re-test. Replace switch ifnecessary.Park Brake IndicatorThe switch remains in the “open” position when the parkbrake lever is not applied.When the parking brake lever is applied, the switch makescontact and sends voltage to the ECU to illuminate“BRAKE” in the instrument cluster rider informationdisplay area (see “Park Brake Indicator”).This warning is used to notify the operator that the parkbrake lever is engaged.When the park brake is fully engaged, “BRAKE” appearsin the rider information display. Engine speed is limited to1300 RPM in all gears, except neutral. If throttle is applied,this limiting feature prevents operation, which protects thepark brake pads from excessive wear.NOTE: If the parking brake is applied the ECU willrev limit the engine at 1300 RPM until the parkingbrake is released. This feature has been added toprevent drive-away with the parking brake applied. If trying to perform an engine diagnostic running testwith the parking brake applied, disconnect theswitch harness connector to allow the engine to revhigher than 1300 RPMs.10.69923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ELECTRICAL2011 Transmission (Gear Position) Switch2012 Transmission (Gear Position) Switch1. Disconnect the transmission switch harness by liftingthe connector lock and pulling on the 6-pin connector.Do not pull on the wiring.1. Disconnect the transmission switch harness by liftingthe connector lock and pulling on the 2-pin connector.Do not pull on the wiring.2. Test transmission switch for continuity in each gearposition and compare to the specification table below.2. Test transmission switch for continuity in each gearposition and compare to the specifications below.1010.79923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ELECTRICALVEHICLE SPEED SENSORSpeed Sensor Location (6x6 Models)Speed Sensor Location (4x4 Models)The speed sensor is located on the right front brake calipermount bracket and can be accessed from the front of thevehicle by turning the steering wheel to the full right.The speed sensor is located in the transmission case andcan be accessed through the rear RH wheel well area.Speed SensorSpeed SensorSpeed Sensor Testing (4x4 Models)Special Tools Required:Speed Sensor Testing (6x6 Models)Special Tools Required:Static Timing Light Harness (PN 2871745)Static Timing Light Harness (PN 2871745)Hall Sensor Probe Harness (PN 2460761)Hall Sensor Probe Harness (PN 2460761)1. Disconnect wire harness from speed sensor andremove sensor from the transmission.2. Connect the wires from the Static Timing LightHarness to the sensor 3 pin connector using the HallSensor Probe Harness (PN 2460761).3. Pass a screwdriver back and forth in front of thesensor tip.4. Be sure connections are good and 9V battery is ingood condition. If the light flashes, the sensor is good.1. Disconnect wire harness from speed sensor andremove sensor from right front brake caliper mount.2. Connect the wires from the Static Timing LightHarness to the sensor 3 pin connector using the HallSensor Probe Harness (PN 2460761).3. Pass a screwdriver back and forth in front of thesensor tip.4. Be sure connections are good and 9V battery is ingood condition. If the light flashes, the sensor is good.10.89923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ELECTRICALREAR DIFFERENTIAL SOLENOIDDifferential Solenoid OverviewThe differential solenoid is located on the right side of thetransmission (4x4) or on the rear gear case (6x6). Thesolenoid actuates an engagement dog, which locks andunlocks the rear differential. Refer to Chapter 8 (4x4) orChapter 7 (6x6) for information on mechanical operation.Differential Solenoid Circuit OperationThe Rear Diff Solenoid Relay is located on the frameunder the rear cargo box.When the switch is pushed to activate “TURF”, a groundis provided to the ECU from the AWD/2WD/TURF Switch.Depending on engine speed, gear position criteria andpark brake input, the ECU energizes the Rear DiffSolenoid Relay allowing it to enable the differentialsolenoid. NOTE: The rear differential will not unlock ifthe parking brake is set.If the differential fails to switch from operational modes: Check the solenoid and relay connectors. Look forloose wires or bad connections.10 Check for power from the relay connector, toensure the solenoid has power to be activated. Check the switch wires for loose connections. Remove solenoid from rear differential and ensurethe solenoid plunger is actuating.CAUTIONDo not power the solenoid with 12 Volts for morethan 1 second, or damage may occur to solenoid.10.99923499 - 2011 / 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc.

ELECTRICALINSTRUMENT CLUSTEROverviewThe instrument cluster displays critical vehicle information to the user. Reference the following page for display functionsand descriptions.NOTE: Some features are not applicable to all models.IMPORTANT: The use of a high pressure washer may damage the instrument cluster. Wash the ve

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