Snowmobile Polaris (2006 year). Instruction - part 65

13.2

ELECTRICAL

GENERAL ELECTRICAL ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.28

OIL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.28

POLARIS ELECTRONIC REVERSE CONTROL (PERC) . . . . . . . . . . . . . . . . . . . . 13.29

DIGITAL WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.30

CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.30

WIRING DIAGRAM WIRE CALL OUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.31

2461155-08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.32

13.3

ELECTRICAL

MULTIMETER

MULTI METER USEAGE

The easiest and most accurate method for testing modern
electrical components is with a digital multitester. Any good
quality multitester will work. However, due to ease of
operation and durability, Polaris recommends the Fluke Model
73 (PN 2870659), or Tektronix DMM155. See photo at right.
This instrument will provide a digital readout of the measured
value of the test being performed.

Please see your Multimeter Owners Manual for operation.

IGNITION TIMING (Carburetor
units)

IGNITION TIMING

NOTE: Always verify timing of engine at room
temperature (68

F / 20

C) only, and at the proper

RPM. If applicable make sure the key switch is in the
PREMIUM mode and the TPS is unplugged.

To obtain the best ignition timing accuracy and reduce the
chance of error, the ignition timing specification is given at a
flat" portion of the advance curve. This flat portion on the
curve is where the base ignition timing is specified. Refer to
the specification chapter for model specific timing
specification. Ignition timing must be checked at the specified
RPM, or an inaccurate timing will result.

If engine damage has occurred due to a suspected ignition
related problem, verify the ignition timing is correct at the
specified operating RPM.

TIMING PROCEDURE (Carburetor units)

Refer to the timing specification charts at the beginning of
this section to determine the proper ignition timing for the
engine you are working on.

Use a dial indicator to place the piston in the proper timing
position and mark the flywheel at this point (follow

procedure outlined in this chapter).

Connect an accurate tachometer and a good quality timing
light to the engine according to manufacturer's
instructions. Disconnect the TPS (Throttle Position
Sensor) connector from carburetors on models with TPS.

Start engine and increase RPM to the point specified in the
timing specifications in Chapter 1. Hold the throttle to
maintain specified timing RPM.

Point the timing light at the timing inspection hole.

With your head positioned so there is a straight line
between your eye, the stationary pointer and the crankshaft
center line, note the relative position between the marked
flywheel line and the stationary pointer. If the stationary
pointer is aligned with the mark made in Step 2, (or within
the acceptable + variance) the timing is correct.

If the pointer is outside the variance, the stator will have to
be rotated either with crankshaft rotation (to retard the
timing) or against rotation to advance it.

NOTE: Rotate stator plate approximately the same
distance as the marks must move. In most cases, the
recoil starter housing, recoil drive hub, and flywheel
must be removed to loosen the stator bolts and
change the timing. On some engines, the stator plate
retaining screws can be accessed through the
flywheel.

Torque stator plate screws and flywheel nut to specified
torque. Apply Loctite 262 (red) to crankshaft flywheel
taper if required. Refer to the Specifications section for
torque specifications and flywheel installation procedure
for engine type.

TIMING CHART (Carburetor units)

If the ignition timing specification is listed in degrees only,
convert to either inches or mm BTDC and use a dial indicator

13.4

ELECTRICAL

to verify timing marks. Disconnect the TPS (Throttle Position
Sensor) connector from carburetors on models with TPS.

Table 13-1:

EH12

EC34-2PM

EC50PL

EC55PM

Domestic 500/600 Domestic 700/900

ROD/

STROKE

(mm)

73mm ROD / 43mm

STROKE

103mm ROD /

55.6mm STROKE

112mm ROD / 60mm

STROKE

120mm ROD /

65mm STROKE

128mm ROD /

64mm STROKE

152mm ROD /

80mm STROKE

Degrees

BTDC

inches

0.0042

0.0002

0.0054

0.0002

0.0058

0.0002

0.0063

0.0002

0.0061

0.0002

0.0077

0.0003

0.0170

0.0007

0.0215

0.0008

0.0232

0.0009

0.0252

0.0010

0.0244

0.0010

0.0308

0.0012

0.0381

0.0015

0.0484

0.0019

0.0521

0.0021

0.0566

0.0022

0.0548

0.0022

0.0692

0.0027

0.0678

0.0027

0.0860

0.0034

0.0926

0.0036

0.1006

0.0040

0.0974

0.0038

0.1231

0.0048

0.1059

0.0042

0.1343

0.0053

0.1447

0.0057

0.1571

0.0062

0.1522

0.0060

0.1922

0.0076

0.1524

0.0060

0.1933

0.0076

0.2083

0.0082

0.2261

0.0089

0.2190

0.0086

0.2766

0.0109

0.2073

0.0082

0.2630

0.0104

0.2833

0.0112

0.3076

0.0121

0.2979

0.0117

0.3763

0.0148

0.2706

0.0107

0.3432

0.0135

0.3698

0.0146

0.4016

0.0158

0.3889

0.0153

0.4913

0.0193

0.3422

0.0135

0.4341

0.0171

0.4677

0.0184

0.5079

0.0200

0.4919

0.0194

0.6213

0.0245

0.4222

0.0166

0.5355

0.0211

0.5770

0.0227

0.6265

0.0247

0.6068

0.0239

0.7665

0.0302

0.5104

0.0201

0.6474

0.0255

0.6976

0.0275

0.7575

0.0298

0.7336

0.0289

0.9267

0.0365

0.6068

0.0239

0.7698

0.0303

0.8294

0.0327

0.9006

0.0355

0.8723

0.0343

1.1018

0.0434

0.7114

0.0280

0.9025

0.0355

0.9724

0.0383

1.0559

0.0416

1.0227

0.0403

1.2918

0.0509

0.8242

0.0324

1.0456

0.0412

1.1265

0.0444

1.2232

0.0482

1.1849

0.0466

1.4965

0.0589

0.9450

0.0372

1.1989

0.0472

1.2917

0.0509

1.4026

0.0552

1.3586

0.0535

1.7159

0.0676

1.0738

0.0423

1.3624

0.0536

1.4678

0.0578

1.5938

0.0628

1.5439

0.0608

1.9499

0.0768

1.2106

0.0477

1.5359

0.0605

1.6548

0.0652

1.7969

0.0707

1.7406

0.0685

2.1984

0.0866

1.3552

0.0534

1.7195

0.0677

1.8526

0.0729

2.0117

0.0792

1.9487

0.0767

2.4612

0.0969

1.5077

0.0594

1.9130

0.0753

2.0611

0.0811

2.2380

0.0881

2.1681

0.0854

2.7382

0.1078

1.6679

0.0657

2.1163

0.0833

2.2802

0.0898

2.4759

0.0975

2.3986

0.0944

3.0292

0.1193

1.8358

0.0723

2.3294

0.0917

2.5098

0.0988

2.7252

0.1073

2.6402

0.1039

3.3342

0.1313

2.0112

0.0792

2.5521

0.1005

2.7497

0.1083

2.9857

0.1175

2.8927

0.1139

3.6530

0.1438

2.1941

0.0864

2.7843

0.1096

3.0000

0.1181

3.2574

0.1282

3.1560

0.1243

3.9855

0.1569

2.3844

0.0939

3.0260

0.1191

3.2603

0.1284

3.5401

0.1394

3.4300

0.1350

4.3314

0.1705

2.5821

0.1017

3.2769

0.1290

3.5307

0.1390

3.8336

0.1509

3.7146

0.1462

4.6906

0.1847

2.7869

0.1097

3.5370

0.1393

3.8110

0.1500

4.1379

0.1629

4.0096

0.1579

5.0630

0.1993

2.9989

0.1181

3.8062

0.1499

4.1010

0.1615

4.4528

0.1753

4.3149

0.1699

5.4484

0.2145

3.2178

0.1267

4.0843

0.1608

4.4007

0.1733

4.7782

0.1881

4.6303

0.1823

5.8466

0.2302

3.4437

0.1356

4.3712

0.1721

4.7098

0.1854

5.1138

0.2013

4.9558

0.1951

6.2573

0.2464

3.6763

0.1447

4.6667

0.1837

5.0282

0.1980

5.4595

0.2149

5.2911

0.2083

6.6805

0.2630

3.9156

0.1542

4.9708

0.1957

5.3559

0.2109

5.8152

0.2289

5.6361

0.2219

7.1159

0.2802

4.1615

0.1638

5.2832

0.2080

5.6926

0.2241

6.1807

0.2433

5.9907

0.2359

7.5633

0.2978

4.4139

0.1738

5.6039

0.2206

6.0381

0.2377

6.5559

0.2581

6.3546

0.2502

8.0225

0.3158

4.6725

0.1840

5.9326

0.2336

6.3924

0.2517

6.9405

0.2732

6.7278

0.2649

8.4933

0.3344

4.9374

0.1944

6.2693

0.2468

6.7552

0.2660

7.3343

0.2888

7.1099

0.2799

8.9754

0.3534

5.2083

0.2051

6.6138

0.2604

7.1263

0.2806

7.7372

0.3046

7.5010

0.2953

9.4687

0.3728

5.4852

0.2160

6.9658

0.2742

7.5057

0.2955

8.1491

0.3208

7.9007

0.3111

9.9729

0.3926

5.7679

0.2271

7.3253

0.2884

7.8931

0.3108

8.5696

0.3374

8.3089

0.3271

10.4878

0.4129

6.0562

0.2384

7.6920

0.3028

8.2883

0.3263

8.9986

0.3543

8.7254

0.3435

11.0131

0.4336

6.3501

0.2500

8.0659

0.3176

8.6912

0.3422

9.4360

0.3715

9.1501

0.3602

11.5486

0.4547

13.5

ELECTRICAL

BATTERY

PREPARING A NEW BATTERY FOR
SERVICE

To ensure maximum service life and performance from a
battery, it must have proper initial servicing. To service a new
battery, the following steps must be taken.

NOTE: Do not service the battery unless it will be
put into regular service within 30 days.

Remove vent plug from vent fitting.

Fill battery with electrolyte to the upper level marks on the
case.

Set battery aside and allow it to cool and stabilize for 30
minutes.

Add electrolyte to bring the level back to the upper level
mark on the case.

NOTE: This is the last time that electrolyte should
be added. If the level becomes low after this point,
add only distilled water.

Charge battery at 1/10 of its amp/hour rating. Example:1/
10 of 9 amp battery =.9 amps, 1/10 of 14 amp battery = 1.4
amps, 1/10 of 18 amp battery = 1.8 amps (recommended
charging rates).

Check specific gravity of each cell with a hydrometer to
ensure each has a reading of 1.270 or higher.

BATTERY TESTING

There are three easy tests which can determine battery
condition. Whenever the complaint is related to either the
starting or charging systems, the battery should be checked
first. Lead-acid batteries should be kept at or as near full
charge as possible. If the battery is stored or used in a partially
charged condition, hard crystal sulfation will form on the
plates, reducing their efficiency and possibly ruining the
battery.

OPEN CIRCUIT VOLTAGE TESTING (OCV)

Battery voltage should be checked with a digital multitester.
Readings of 12.6v or less require further battery testing and
charging.

SPECIFIC GRAVITY TEST

A tool such as the battery hydrometer (PN 2870836) can be
used to measure electrolyte strength or specific gravity. As the
battery goes through the charge/discharge cycle, the
electrolyte goes from a heavy, more acidic state at full charge
to a light, more water state when discharged. The hydrometer

can measure state of charge and differences between cells in a
multi-cell battery. Readings of 1.270 or greater should be
observed in a fully charged battery. Differences of more
than.025 between the lowest and highest cell readings indicate
a need to replace the battery.

LOAD TEST

NOTE: This test can only be performed on machines
equipped with electric start. This test cannot be
performed if the engine or starting system is not
working properly.

A battery may indicate a fully charge condition on the OCV
test and the specific gravity test, but still not have the storage
capacity necessary to properly function in the electrical
system. For this reason, a battery capacity or load test should
be conducted whenever poor battery performance is
encountered.

To perform the test, hook a multitester to the battery in the
same manner as in the OCV test. The reading should be 12.6
volts or greater. Engage the electric starter and view the
registered battery voltage while cranking the engine. Continue
the test for 15 seconds. During this cranking period, the
observed voltage should not drop below 9.5 volts. If the
beginning voltage is 12.6 or higher and the cranking voltage
drops below 9.5 volts during the test, replace the battery.

REFILLING A LOW BATTERY

The normal charge/discharge cycle of a battery causes the cells
to give off gases. These gases, hydrogen and oxygen, are the

Table 13-2: Battery Voltage

STATE OF CHARGE

CONVENTIONAL

LEAD-ACID

YUMACRON TYPE

100% CHARGED

12.60v

12.70v

75% CHARGED

12.40v

12.50v

50% CHARGED

12.10v

12.20v

25% CHARGED

11.90v

12.00v

0% CHARGED

< 11.80v

< 11.90v

Battery voltage per cell

100% CHARGED

1.265v

1.275v

75% CHARGED

1.210v

1.225v

50% CHARGED

1.160v

1.175v

25% CHARGED

1.120v

1.135v

0% CHARGED

< 1.100v

< 1.115v

Content .. 63 64 65 66 ..