Polaris RANGER 1000 2020 - Chapter 12 Chassis; Body Electrical

12
9850045 R01 - 2020-2021 RANGER 1000 Service Manual
© Copyright Polaris Inc.
12.1
CHASSIS / BODY ELECTRICAL
CHAPTER 12
CHASSIS / BODY ELECTRICAL
GENERAL INFORMATION - ELECTRICAL SYSTEM . .. . .. . .. . .. .. . .. . .. . .. . ... ... . .. . .. . .. . ... . .. . ..12.3
SERVICE NOTES - ELECTRICAL. .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... . .. . .. . .. . ... . .. . .. . .. .12.3
BODY ELECTRICAL SPECIFICATIONS . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . .12.4
FUSE BOX / CIRCUIT PROTECTION . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... .. .. . .. . .. . ... ... ... . .. . ..12.5
FUSE BOX BREAKOUT . . .. . .. . ... .. .. . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ..12.5
RELAY OPERATION. ... ... . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . .12.7
VEHICLE HARNESS SERVICE .. . .. . .. . .. . ... ... . .. . .. . .. . .. . . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... . .. . ..12.9
CHASSIS HARNESS ROUTING . . .. . .. . ... . .. . .. . .. . .. . ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . .12.9
CHASSIS HARNESS REMOVAL . . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. 12.16
CHASSIS HARNESS INSTALLATION .. . .. . .. . ... .. .. . .. . .. . .. . ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . . 12.16
SWITCHES / CONTROLS SERVICE ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . ... 12.17
IGNITION KEY SWITCH . . .. . .. . ... .. .. . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... 12.17
TRANSMISSION (GEAR POSITION) SWITCH .. . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . .. . 12.18
SEAT BELT SWITCH . .. . ... .. .. . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . 12.18
BRAKE PEDAL SWITCH INSPECTION .. . ... ... . .. . .. . .. . .. . ... . .. . .. . .. . .. . ... .. .. . .. . .. . .. . ... ... 12.19
ALL WHEEL DRIVE CIRCUIT SERVICE.. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . .. . ... . 12.19
AWD / 2WD / TURF SWITCH . . .. . ... ... . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . .. . ... ... . .. . .. . 12.19
OPERATION OVERVIEW. ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . . 12.19
DIAGNOSING SYSTEM FAILURES . .. . .. . ... . .. . .. . .. . .. . ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . . 12.19
VEHICLE SPEED SENSOR SERVICE .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... . .. . .. . .. . ... . .. . .. . . 12.20
SPEED SENSOR LOCATION . .. . .. . ... . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . 12.20
SPEED SENSOR TESTING . . .. . .. . .. . ... . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . ... ... . .. . .. . ... ... . .. . 12.21
REAR DIFF SOLENOID SERVICE . . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . 12.21
DIFFERENTIAL SOLENOID OVERVIEW. . .. . .. . .. . ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. 12.21
DIFFERENTIAL SOLENOID CIRCUIT OPERATION . . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . .. . .. . . 12.21
DIFFERENTIAL SOLENOID REPLACEMENT .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. 12.22
INSTRUMENT CLUSTER SERVICE .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . .. . ... ... . .. . .. . ... ... . .. . .. . .. . . 12.23
INSTRUMENT CLUSTER PINOUTS .. ... . .. . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... . .. . .. . .. . . 12.23
INSTRUMENT CLUSTER SERVICE . . .. . .. . ... . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . ... ... . .. . .. . .. . ... . .. . 12.23
CHARGING SYSTEM SERVICE . . .. . .. . ... ... .. .. . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. 12.24
STATOR. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . 12.24
STATOR INSPECTION . . .. . .. . .. . ... ... . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . .. . ... ... . .. . .. . 12.24
STATOR SERVICE . ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . 12.24
REGULATOR / RECTIFIER REPLACEMENT. .. .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . 12.26
CHARGING SYSTEM TESTING FLOW CHART ... . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... 12.26
CHARGING SYSTEM TROUBLESHOOTING . . .. .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... .. .. . .. . .. . ... ... 12.28
CHARGING SYSTEM “BREAK EVEN” TEST . .. . .. . .. . ... ... . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . . 12.28
CHARGING SYSTEM STATOR (ALTERNATOR) TESTS.. . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. 12.28
REGULATOR TESTING (900 WATT) . . ... . .. . .. . .. . ... ... .. .. . .. . .. . ... ... . .. . .. . .. . .. . ... . .. . . 12.29
BATTERY SERVICE.. . .. . .. . .. . .. . ... ... . .. . .. . .. . . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . .. . 12.30
BATTERY SPECIFICATIONS . . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. 12.30