Snowmobile Polaris (2006 year). Instruction - part 68

13.14

ELECTRICAL

TROUBLESHOOTING CHARTS

NO SPARK

Table 13-7: No Spark Condition

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

NO

J

 

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?

NO

J

All except 3 cylinders: 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. 
(See ignition data)

All 3 cylinders: Disconnect and check the secondary 
ignition coil resistances. Refer to the resistance values 
listed in wiring diagrams. If the coil resistance values 
are within specs, replace the CDI module.

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.

Table 13-8: Incorrect Timing (Advanced/Retard)

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

NO

J

 

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?

NO

J

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?

NO

J

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?

NO

J

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

13.15

ELECTRICAL

IQ BLINK CODES

A warning system is incorporated into the speedometer that 
will inform the rider of a code that has been set by a sensor 
that was operated beyond the normal operating ranges.

The check engine LED will display a blink code when ever the 
ECU determines there is a problem with one or more of the 

sensor listed. Hook up Digital Wrench to troubleshoot, fix and 
clear the codes.

The blinking LED can be de-coded for diagnosis and if two or 
more codes are present at the same time the code will blink in 
turn of each other.

When a blink code is displayed, the CHECK ENGINE light 
will illuminate for 1/2 second “on” and 1/2 second “off” with a 
1 second “off” interval between close.

Table 13-9: IQ Blink Codes

SENSOR

LED

EXPLINATION

Throttle Sensor

1

Sensor signal is below 0.7 volts or above 4.39 volts

Water Temperature Sensor

2

Sensor signal is below 0.1 volts or above 4.8 volts

Air Temperature Sensor

3

Sensor signal is below 0.19 volts or above 4.9 volts

Barometric Pressure Sensor

4

Sensor signal is below 1.25 volts or above 3.23 volts

Exhaust Temperature Sensor

5

This code is set of the engine has been running above 3000 RPM for more than 2 minuets and 
the sensor voltage is below.06 volts or above 4.9 volts.

Detonation Sensor

6

This blink code is set if the engine speed is above 6000 RPM and the DET signal is below 
1.23 volts or above 4.3 volts for more than 2 seconds

Injector 7

Injector 

disconnect

EV Solenoid

8

An “open circuit” condition is detected in the exhaust valve solenoid.

Ignition

9

Ignition coil disconnection

Crank Position Sensor

10

5 and 2 tooth disconnection

13.16

ELECTRICAL

TPS TOOL SET UP

The TPS comes set from the factory and should not need 
adjustment. However, upon removal of the TPS, you must 
mark the TPS position on the carburetor and replace it in the 
exact same position as removal. Polaris has developed a TPS 
test kit for aid in setting the Throttle Position Sensor to 
specification.

TPS SET UP

1.

Illustration at right shows the TPS sensor kit PN 2201519.

2.

Make sure your 9 volt battery is in good condition by
inserting the black volt meter probe from your Fluket
meter in the black terminal and the red probe into the pink
terminal. Voltage should read 4.99 to 5.01 volts. If not, try
a new 9 volt battery.

3.

Remove the connector from the TPS.

4.

Install test harness connector on TPS.

5.

Insert red voltmeter lead into yellow terminal, and black
lead to black terminal. Slowly open throttle and check for
smooth voltage change.

NOTE:  The fluke meter will change scales and show 
O.L. momentarily when throttle is opening.

TPS ADJUSTMENT

1.

Loosen the two screws that hold the TPS on the
carburetors.

2.

Turn the TPS clockwise to decrease voltage, or
counterclockwise to increase voltage.

3.

When the TPS is set to the desired voltage, tighten the
holding screws and verify voltage is 4.0 - 4.2 volts at wide
open throttle.

4.

When the TPS is set and voltage is verified, remove the
tester and re-install the snowmobile TPS harness.

5.

When storing the TPS tester, remove the red terminal of
the tester and insert it in the blank terminal of the harness.

Black Probe

Red Probe

13.17

ELECTRICAL

CLEAN FIRE ELECTRICAL

IQ THROTTLE POSITION SENSOR

When the sensor is inoperative or disconnected the system will 
switch to a LIMP HOME" mode. Limp Home mode reduces 
performance to a default value and monitors other sensors.

IQ TEMPERATURE LIGHT

The TEMP light (A) is controlled by the CDI using water 
temperature input from the water temp sensor (B), throttle 
position input (TPS) and RPM input. The water temp sensor is 
a thermistor. As the temperature increases the resistance 
decreases. Each input has thresholds programmed into the CDI 
for when to illuminate the TEMP light according to coolant 
temp, throttle position (TPS) and engine speed (RPM). 

For example, the TEMP light will come on at idle (under 2000 
RPM, 0% throttle) and coolant temperature of 230_F (110_C). 
Timing retard initiates at 176_F and a TPS of over 80-100%. 
For more severe conditions, the engine fail-safe is turned on at 
high TPS input and high temps.

LAMP CIRCUIT TEST

1.

Ground the Black/White wire from the Temperature light.

2.

Run the machine, and light should be on.

THERMISTOR SENSOR TEST

At room temperature 68_ F (20_ C) the Thermistor should 
read 2190 to 2575 

Ω. See chart below for other temperature 

resistances.

Table 13-10: IQ Temperature Sensor 

Resistance Range

TEMPERATURE _F (_C)

Ω RESISTANCE RANGE

68 (20)

2189 - 2675

149 (65)

455 - 566

203 (95)

197 - 240

239 (115)

120 - 147

275 (135)

77 - 94

CAUTION

I

F

 

ATTEMPTING

 

TO

 

HEAT

 

THE

 

SENSOR

, 

HEAT

 

ONLY

 

IN

 

A

 

WA

-

TER

 

BATH

. N

EVER

 

SUBJECT

 

THE

 

SENSOR

 

TO

 

AN

 

OPEN

 

FLAME

 

TO

 

ATTEMPT

 

TO

 

CLOSE

 

THE

 

CONTACTS

 

AS

 

SENSOR

 

DAMAGE

 

MAY

 

RESULT

.