2005 Polaris Sportsman 400/500 Service Manual, Page 272Get this manual
ELECTRICAL
SPEEDOMETER TROUBLESHOOTING
TEST REVERSE SPEED LIMITER ACTIVATED IN FORWARD GEAR (Engine loses spark when vehicle speed is above 7-9 mph
START HERE
INSTRUMENT CLUSTER FUNCTION OK? CHECK SPEEDOMETER (PERFORM TEST 2)
16 Pin Connector
1OrangeWhite- 12V Constant 2RedWhite- 12V Switched 3GreyOrange- ModeOverride button 4Black- Ignition Kill 5Green 6Blue 7YellowRed- RPM Input 8Brown- Ground 9Blue White- Engine Overheat Switch 10NC 11NC 12PurpleWhite- Fuel Sender (not used) 13BrownRed- Neutral 14White 15NC 16BrownWhite- AWD Control -
SHIFT TO LOW OR HIGH GEARSDOES GEAR INDICATOR DISPLAY CORRECTLY?
CHECK FUELIGNITION SYSTEMS
TURN KEY SWITCH OFF REMOVE 16 PIN PLUG FROM BACK OF INSTRUMENT CLUSTER RESTART ATV AND TEST DRIVE
PROBLEM REMAINS?
REPLACE SPEEDOMETER
TEST TRANSMISSION SWITCH CHECK RELATED WIRING