[Un4tune8]

Hi All,
New member and new first time Polaris owner!

I recently bought this ATV and since I am new to them I missed these issues when I bought it. I have gone riding 3 times and it runs and drives great and has low miles for an 05 (780mi)

It started when I changed the oil and tried to enter diagnostic mode to reset the maintenance notification (flashing wrench). It will not enter diag mode. I started my research and find that if the ECU doesn't know you are in Neutral that it won't enter the mode. This led me to realize I didn't have shift indicator at all. They only light up for a second when I first turn the key on. Most people are also saying that in this condition the AWD won't work. I have jacked it up and find that all 4 wheels turn all the time no matter what the AWD switch is set to. I found a few more quirks and will list them here below along with what I have done so far. I noticed that there are lot of different grounds that pretty much end up in the same places but I could see how a bad ground in one area could lead to only a few things not working. I know the next thing to look at is the resistor module but then I'm thinking how would this effect the AWD, trip reset and diag mode. Anyhow that's why I am here!

Issues:
-No shift indicators at all
-Won't go into diag mode by holding the mode button while turning the key on when in Neutral (or any gear)
-Won't reset trip
-No AWD icon except when pushing the override button
-Always in AWD

What I have looked at:
-I removed the plug to the trans gear position switch. I used a jumper to connect the common wire to the other connectors to see if the display would show a gear and it does not. So I am thinking that the trans switch is ok.
-With all 4 wheels off ground AWD is always on no matter where the AWD switch is

I am not the best at electronics but not bad with some guidance. I have been looking at the schematics of the service manual and see how I might check the resistance of the resistor module but since I don't get a reading on the display with my jumper test I'm thinking there could be a continuity problem right off the bat or there is an issue with the Speedo or ECO possibly.

Here is what I was going to do next and I am not sure if I do it with key on or off or how I might damage it:
Disconnect 16 pin from speedo and test the resistance with a multimeter. I assume I would have the multimeter black lead on the pin that is the common that comes from the trans switch and the red lead on one of the connectors coming from resistor module. I am unsure if I need to do anything with the white wire though that also comes from the resistor module

If all looked good I was going to then plug that speedo connector back in and go to the ECM. There are some wires related that then go from the spedo over to the ECM but I am unsure how or what to check there.

I have a weird feeling that my problem is going to be more related to the Speedo module or main ECM than it is going to be from this resistor pack unless it is possible for the resistor module to short things out.

TIA guys!

 

[FPD218]

Welcome to the forum

Your question has now been logged into the queue and the next available form member will answer you shortly

 

[Un4tune8]

Just a quick follow up. I know I said ECO when I meant ECM. I also forgot to mention that I am also going to just clean the contacts and apply some dielectric grease at the resistor module, speedo and ECM to see if anything changes.

 

[latebird]

Note - when not in AWD but no resistance to the front wheels to rotating, the front wheels will rotate due to friction within the drive line - just jack up the rear end with a wheeled floor jack and see if the front wheels pull the vehicle when not in AWD.

 

[Un4tune8]

Note - when not in AWD but no resistance to the front wheels to rotating, the front wheels will rotate due to friction within the drive line - just jack up the rear end with a wheeled floor jack and see if the front wheels pull the vehicle when not in AWD.

I was wondering about that before so I tried to grab a front wheel and I couldn't stop it but I think I will confirm as soon as I can. Thanks for the comment.

 

[latebird]

You might have to put in reverse momentarily to unlock the front - if that doesn't work, then unplug the AWD coil connector - if it won't unlock, it need to be serviced.

 

[Un4tune8]

You might have to put in reverse momentarily to unlock the front - if that doesn't work, then unplug the AWD coil connector - if it won't unlock, it need to be serviced.

Cool, another thing I can try at the same time when I get back to it. If the hub needs to be serviced though would that cause any of the other things? (no AWD light, no shift indicators, can't reset trip)

 

[latebird]

If the hub needs to be serviced though would that cause any of the other things? (no AWD light, no shift indicators, can't reset trip)

Hub service? The AWD Hilliard is in the front gearcase - servicing the hubs would do nothing other than complete routine maintenance.

No, the AWD icon (not light), gear indicator and trip reset would not be affected - that will be a wiring issue (connections or sensors) or a faulty instrument.

 

[Un4tune8]

Hub service? The AWD Hilliard is in the front gearcase - servicing the hubs would do nothing other than complete routine maintenance.

No, the AWD icon (not light), gear indicator and trip reset would not be affected - that will be a wiring issue (connections or sensors) or a faulty instrument.

Okay, Hilliard is a new word for me!. I saw some others that changed the armature plate to fix the same issue so I thought that is where you were headed. It seems like I have the right idea about the wiring or faulty instrument though, now to pinpoint hopefully. I will get back maybe later today with my findings. Thank you again for your input.

 

[Un4tune8]

Hi All,
New member and new first time Polaris owner!

I recently bought this ATV and since I am new to them I missed these issues when I bought it. I have gone riding 3 times and it runs and drives great and has low miles for an 05 (780mi)

It started when I changed the oil and tried to enter diagnostic mode to reset the maintenance notification (flashing wrench). It will not enter diag mode. I started my research and find that if the ECU doesn't know you are in Neutral that it won't enter the mode. This led me to realize I didn't have shift indicator at all. They only light up for a second when I first turn the key on. Most people are also saying that in this condition the AWD won't work. I have jacked it up and find that all 4 wheels turn all the time no matter what the AWD switch is set to. I found a few more quirks and will list them here below along with what I have done so far. I noticed that there are lot of different grounds that pretty much end up in the same places but I could see how a bad ground in one area could lead to only a few things not working. I know the next thing to look at is the resistor module but then I'm thinking how would this effect the AWD, trip reset and diag mode. Anyhow that's why I am here!

Issues:
-No shift indicators at all
-Won't go into diag mode by holding the mode button while turning the key on when in Neutral (or any gear)
-Won't reset trip
-No AWD icon except when pushing the override button
-Always in AWD

What I have looked at:
-I removed the plug to the trans gear position switch. I used a jumper to connect the common wire to the other connectors to see if the display would show a gear and it does not. So I am thinking that the trans switch is ok.
-With all 4 wheels off ground AWD is always on no matter where the AWD switch is

I am not the best at electronics but not bad with some guidance. I have been looking at the schematics of the service manual and see how I might check the resistance of the resistor module but since I don't get a reading on the display with my jumper test I'm thinking there could be a continuity problem right off the bat or there is an issue with the Speedo or ECO possibly.

Here is what I was going to do next and I am not sure if I do it with key on or off or how I might damage it:
Disconnect 16 pin from speedo and test the resistance with a multimeter. I assume I would have the multimeter black lead on the pin that is the common that comes from the trans switch and the red lead on one of the connectors coming from resistor module. I am unsure if I need to do anything with the white wire though that also comes from the resistor module

If all looked good I was going to then plug that speedo connector back in and go to the ECM. There are some wires related that then go from the spedo over to the ECM but I am unsure how or what to check there.

I have a weird feeling that my problem is going to be more related to the Speedo module or main ECM than it is going to be from this resistor pack unless it is possible for the resistor module to short things out.

TIA guys!

I finally had time to troubleshoot. Using a multi-meter I determined the trans gear switch was ok. Next I checked the resistor module. I could not get ohm readings from it although I could get a voltage reading. So, I ordered a new resistor module and just got done splicing it in. Boom! fixed all my problems. I now have gear indicator lighting up. I can reset the trip meter. The 4x4 indicator now works with the handle bar switch and I can enter maintenance mode to reset the flashing wrench oil change interval. One thing I have left to check is if I will stay in 2 wheel drive. I'll let you know and thank for the help.