Fan Trouble Shooting

76-2013 Fan Trouble Shooting: Particle Separator - Polaris RZR Pro XP

Step 1.

Before You Begin:

1.1. Make sure the vehicle is in a safe area, the vehicle is in Park, and the Parking Brake set.
1.2. Do not work on the vehicle while the engine or other components are hot.
1.3. Familiarize yourself with and locate the Power Harness

Step 1. (continued)

1.4. Familiarize yourself with and locate the Control Board Harness, also known as the Y-Splitter Harness.

Step 1. (continued)

1.5. Make sure you have a quality Digital Multimeter with needle probe attachments.
1.6. If you have any questions or are unsure about any of the instructions, please call Customer Support at (909) 947-001

Step 2.

Verify the Power Harness has power from the vehicle’s Pulse Bar

2.1. Locate the Polaris Pulse Bar towards the front of the vehicle.
2.2. Remove the Polaris Pulse Connector on the Power Harness from the vehicle’s Pulse Bar.

Step 2 (continued)

Verify the Power Harness has power from the vehicle’s Pulse Bar

2.3. Carefully use a Digital Multimeter to verify that there is battery power being delivered to the Pulse Bar between the two outside terminals. Battery power should be about 12 VDC. Be careful not to short the Pulse Bar when measuring the voltage.

Step 2. (continued)

Verify the Power Harness has power from the vehicle’s Pulse Bar

2.4. Carefully use a Digital Multimeter to verify that there is battery power being delivered to the Pulse Bar between the middle and top terminals when the Ignition Switch is in the “Key-On” position. Be careful not to short the Pulse Bar when measuring the voltage.
2.5. Place the Ignition Switch to the “Off” position.
2.6. If you are not getting any voltage readings from the vehicle’s Pulse Bar, see the vehicle manufacturer’s manual for troubleshooting the Pulse Bar.
2.7. Re-connect the Power Harness Pulse Connector to the vehicle’s Pulse Bar. Make sure the Pulse Connector is not loose and fully connected to the Pulse Bar.

Step 3.

Verify the condition of the Power Harness fuse and relay.

3.1. Locate the Fuse & Relay Block on the Power Harness. It will be located within 2 ft of the Pulse Connector.
3.2. Depress the clip and slide the Cover off.

Step 3. (continued)

3.3. Inspect the fuse and replace if blown or damaged.

3.4. Check the operation of the relay by turning the Ignition Switch to the “Key-On” position. You should hear the relay mechanically “click” whenever you toggle the Ignition Switch to the “Key-On” or “Key-Off” position. Replace the relay if it is damaged or not working properly.

3.5. Put back the Block Cover.

Step 4.

Check Power Harness 2PF Connector for power.

4.1. Locate the 2PF Power Connector on the Power Harness and disconnect it from the 2PM Power Connector on the Control Board Harness.
4.2. Place the Ignition Switch in the “Key-On” position.
4.3. Using a Digital Multimeter and needle probes, check the voltage at the 2PF Power Connector. Voltage should be approximately 12 VDC. Be careful to keep the needle probes separated when reading the voltage or you will short the Power Connector and blow the fuse in the Fuse and Relay Block.
4.4. If you have approximately 12 VDC at the 2PF Connector, the Power Harness is working fine.
4.5. If you do not measure any voltage at the 2PF Connector and have verified Step 2 and 3 were ok, then you will need to replace the Power Harness, part number AI2229-00. Please call Customer Service at (909) 947-0015.
4.6. Place the Ignition Switch back to the “Off” position.

Step 5.

Check Control Board Harness 3PF Fan Connector for power.

5.1. Locate the 3PF Fan Connector on the Control Board Harness and disconnect it from the Scavenge Fan on the Particle Separator.
5.2. Connect the 2PF Power Connector on the Power Harness and connect it to the 2PM Power Connector on the Control Board Harness.
5.3. Place the Ignition Switch in the “Key-On” position.
5.4. Using a Digital Multimeter and needle probes, check the voltage between the red and black wires at the 3PF Fan Connector. Be careful to keep the needle probes separated when reading the voltage or you will short the Fan Connector and blow the fuse in the Fuse and Relay Block.
5.5. You should have approximately 12 VDC between the red and black wires when the Ignition Switch is in the “Key-On” position.
5.6. If you do not measure any voltage between the red and black wires, replace the Control Board Harness, part number AI2367-00. Please call Customer Service at (909) 947-0015.
5.7. Place the Ignition Switch back to the “Off” position.

Step 6.

Check the Control Board Harness 4PF Ignition Sensor Connector for power.

6.1. Locate the 4PF Ignition Sensor Connector on the Control Board Harness and make sure it is connected to the Ignition Sensor.
6.2. Place the Ignition Switch to the “Key-On” position.
6.3. Using a Digital Multimeter and needle probes, back probe the 4PF Ignition Sensor Connector and check to see if you have approximately 12 VDC between the red and black wires. Be careful to keep the needle probes separated when reading the voltage or you will short the Power Connector and blow the fuse in the Fuse and Relay Block. Also, when back probing this connector, slide the needle probe between the wire and the seal until you feel it contact the connector’s conductive pin. You will have to hold the needle probe properly to maintain contact with the conductive pin. Moving the needle probe slightly against the connector pin until you get a reading will also help you position the needle probe. Be patient until you get the hang of it.
6.4. If you did not measure any voltage between the red and black wire on the 4PF Connector during Key-On, replace the Control Board Harness, part number AI2367-00. Please call Customer Service at (909) 947-0015.
6.5. Place the Ignition Switch to the “Off” position.

Step 7.

Check the Operation of the Ignition Sensor.

7.1. Locate the 4PF Ignition Sensor Connector on the Control Board Harness and make sure the Ignition Sensor is properly connected to the 4PF Connector.
7.2. Locate the Ignition Sensor and make sure that it is installed correctly onto the positive ignition coil wire (orange wire). Make sure that the top clip is touching the bottom clip on the inside. Also make sure there are zip ties on each side of the clips to ensure the coil wire is firmly attached through the ignition sensor clips.
7.3. Place the Ignition Switch in the “Key-On” position.

Step 7. (continued)

7.4. Using a Digital Multimeter and needle probes, back probe the 4PF Ignition Sensor Connector and check to see if you have approximately 0.1 VDC between the brown and black wires. Be careful to keep the needle probes separated when reading the voltage or you will cause an electric short and possibly blow the fuse in the Fuse and Relay Block. Also, when back probing this connector, slide the needle probe between the wire and the seal until you feel it contact the connector’s conductive pin. You will have to hold the needle probe properly to maintain contact with the conductive pin. Moving the needle probe slightly against the connector pin until you get a reading will also help you position the needle probe. Be patient until you get the hang of it.
7.5. Start the vehicle engine and let it idle.
7.6. Using the same technique in Step 7.4, use a Digital Multimeter and back probe the 4PF Ignition Sensor Connector and check the voltage between the brown and black wire. The voltage should bounce between 1-3 VDC at engine idle.

Step 7. (continued)

7.7. If you measured the same voltage of 0.1 VDC between the brown and black wire on the 4PF Connector during engine idle as in Key-On, recheck the Ignition Sensor mounting as outlined in Step 7.2.
7.8. Have someone rev the engine to a steady 3000 rpm.
7.9. Using the same technique in Step 7.4, use a Digital Multimeter and back probe the 4PF Ignition Sensor Connector and check the voltage between the brown and black wire. The voltage should bounce between 2.8-3.5 VDC at 3000 rpm engine speed.
7.10. If you do not get the voltage readings listed above at Key-On, Idle, and 3000 rpm, replace the Ignition Sensor, part number AI2497-00. Please call Customer Service at (909) 947-0015.
7.11. Turn the Ignition Switch to the “Off” position to turn the engine off.

Step 8.

Check the Control Board Harness 3PF Fan Connector for control voltage.

8.1. Locate the 4PF Ignition Sensor Connector on the Control Board Harness and make sure the Ignition Sensor is properly connected to the 4PF Connector.
8.2. Locate the 3PF Fan Connector on the Control Board Harness and disconnect it from the Scavenge Fan on the Particle Separator.
8.3. Place the Ignition Switch in the “Key-On” position.
8.4. Using a Digital Multimeter and needle probes, check the voltage between the yellow and black wire on the 3PF Connector. You should have approximately 1.2 VDC at Key-On. Be careful to keep the needle probes separated when reading the voltage or you will short the Fan Connector and possibly blow the fuse in the Fuse and Relay Block.

Step 8. (continued)

8.5. Start the engine and let it idle.
8.6. Using a Digital Multimeter and needle probes, check the voltage between the yellow and black wire on the 3PF Connector. You should have approximately 2.7 VDC at engine idle. Again, be careful to keep the needle probes separated when reading the voltage or you will short the Fan Connector and possibly blow the fuse in the Fuse and Relay Block.
8.7. Have someone rev the engine to a steady 3000 rpm.
8.8. Using a Digital Multimeter and needle probes, check the voltage between the yellow and black wire on the 3PF Connector. You should have approximately 4.0 VDC at 3000 rpm. Again, be careful to keep the needle probes separated when reading the voltage or you will short the Fan Connector and possibly blow the fuse in the Fuse and Relay Block.
8.9. If you did not measure any of the specified voltages between the yellow and black wire on the 3PF Connector during Key-On, Idle, and 3000 rpm, replace the Control Board Harness, part number AI2367-00. Please call Customer Service at (909) 947-0015.
8.10. Turn the Ignition Switch to the “Off” position to turn the engine off.

Step 9.

Check the Operation of the Fan

9.1. Make sure the Power Harness is properly connected to the Control Board Harness. Also verify that the Ignition Sensor and Particle Separator Fan are connected to the Control Board Harness.
9.2. Place the Ignition Switch in the “Key-On” position. The Fan should be running at about 20% speed.
9.3. Turn the engine on and let it idle. The Fan should be running at about 60% speed.
9.4. Have someone rev the engine to a steady 3000 rpm. The fan should be running at 100% speed.

Step 9. (continued)

9.5. If your fan does not run at the various speeds listed above for Key-On, Idle, and 3000 rpm, turn your engine off and disconnect the fan from the Control Board Harness.
9.6. Remove the 4 screws holding the fan cover and carefully remove the fan and cover.
9.7. Inspect the fan making sure it can spin freely and remove any debris that could be preventing the fans from spinning.
9.8. Replace the fan and cover and tighten the 4 screws. Make sure to replace the fan in the proper direction so that it will blow the air out of the cover.
9.9. Reconnect the fan to the Control Board Harness and repeat Steps 9.1-9.4.
9.10. If your fan does not run at the various speeds listed above for Key-On, Idle, and 3000 rpm, your fan, part number AI2300-00, may need to be replaced. Please call Customer Service at (909) 947-0015.
9.11. If your fan turns on but the speed remains low, check the operation of the Ignition Sensor listed in Step 7.
9.12. If the fan turns on but the speed remains high, check the operation of Control Board Harness as listed in Step 5, 6, and 8. Also check the Ignition Sensor listed in Step 7.

Step 10.

If the Power Harness Fuse Keeps Blowing:

10.1 Disconnect the Power Harness from the Control Board Harness.
10.2. Disconnect the Fan and Ignition Sensor from the Control Board Harness.
10.3. Place the Ignition Switch in the “Key-On” position.
10.4: Make sure the Power Harness Fuse is in good working condition.

Step 10. (continued)

10.5. Determine the device that causes the fuse to blow by connecting each device one at a time in the following order.

A: Reconnect the Control Board Harness to the Power Harness and check the fuse.
B: Reconnect the Ignition Sensor to the Control Board Harness and check the fuse.
C: Reconnect the Fan to the Control Board Harness and check the fuse

10.6. Replace the device that is causing the fuse to blow. Please call Customer Service at (909) 947-0015.

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Fan Trouble Shooting

76-2013 Fan Trouble Shooting: Particle Separator - Polaris RZR Pro XP

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