nothing on the speedo works no lights no odo no speed and also I am no electrical wiz so my question is could it be something other then the internals on the speedo making it not work. When I grabbed the device with my tweezers, the case crumbled before I ever applied heat, clear evidence of thermal damage. Both the speedometer should go up and the odometer should (slowly!) In the next segment, well learn about the steps to fix this issue. In the next segment, well learn about the steps to fix this issue. Thank you so much for this! You normally perform a break-in oil and filter change every run-day or 24 engine hours. In the picture, the "bad" part had no visual indication of there being anything wrong with it. and verifying that there is conductivity (500-700 millivolts) in only ONE direction.Properly checking a Zener diode is trickier since they will test as a diode in one direction, but they are supposed to "break down" at a specified voltage in the opposite: If exposed to excess current, they can still check out as diodes, but their "Zener" voltage can drift - and this could only be properly tested using a simple test fixture (resistor, Zener in series).If there is any doubt at all, simply replace the Zener! I don't have a device to do that I don't think. Before thinking, I removed the TIP48 from the board, but then tested it using both diode test feature and transistor test feature on my DMM, and I believe the TIP48 is functioning as desired. Hi KA7OEI,Thanks for the awesome write up with great detail and documentation.I noticed in of your photos there is a paper document with what looks like to be oem schematic of the speedo with possible pin out. As you can see, there are two SMD diodes and a SMD transistor in the area where your through-hole diode and MPSA42 were. The integrated circuit in the speedometer contains a feedback loop to the engine. Thanks again, very helpfulBtw if you want pictures I still have the unit disassembled. As I was almost finished with the repair, the LCD fell off including the clear plastic piece that holds the LCD and Zebra Strips to the circuit board. Mark's deep understanding of various types of vehicles such as UTVs, ATVs, cars, Trucks, and lawnmowers which allows him to provide valuable insights and information. 1-3 numbers followed by the letter "k" or, less likely some numbers in front of "M") or just three numbers together - this indicating the resistance value of the potentiometer.Best of luck! Thanks for the follow-up - and I'll be interested in either your success or failure!An interesting quirk about DigiKey is that if you send them a check or money order in snail mail, shipping is free - at least for small orders - something to remember if you need a small number of parts, but aren't in any sort of hurry! Polaris Sportsman 500 Speedometer Not Working - 5 Reasons - The Automobily You can squeeze the clips with your right hand and squeeze the cable with your left thumb. My 4 wheel drive works properlyon and off. I get full deflection to 60MPH reading at around 320Hz.In case anyone is interested, the DigiKey part I ordered is 1727-4851-1-ND mfr part # BC846,215 and can be found at this URL as of this writing:https://www.digikey.com/product-detail/en/BC846%2c215/1727-4851-1-ND/2531351To commenter Ron Stier on October 6, 2018 above. The voltage should be no more than 2-3 volts below the supply voltage to the speedo. I'm not sure how anyone was adding attachments to their comments as I don't see an option to do so. Again, there seems to be a (newer?) Think maybe it was just stuck due to long time storage. Only burn marks I found is on one thing. I bought it used just this past summer, fully aware that the speedometer was not working. I noticed in your pics that you were able to 'inject a signal' to get it to read a speed. I got it on ebay and I was told it works properly. I think I messed up. . Test-fit the face plate to make sure that you pushed the needle on far enough and is not rubbing on the inside face plate. Put out all the parts of the speedometer and wipe them until their clean. Not having seen one of those speedos myself, I really can't offer any specific advice as to what goes wrong with them other than to look for similar-type problems - and, as I saw in one of the pictures sent to me, some "vented" capacitors (e.g. The hour meter still works they will change as time permits and the lights still work. The TIP48 is through-hole, but the diode and MPSA42 have beenreplaced with SMDs. I bought it several years ago in many boxes. Guy this was the most resourceful blog ever. a triangle pointing at a line. Headlights and tail light. We will be looking into all the reasons why and how to fix those. 4841 S Overland Dr, Tucson, AZ, United States, 85714. Wondering if it might be the problem. They are crafted for lightweight and multi personnel long-range trips. don't crimp the ring back together just yet) and try it.As noted in the article, even the slightest mote of dust on the Zebra strip will make the LCD flaky with some missing segments, hence the cotton swabs and keeping dust and strands away from the zebra strip, the back of the LCD and the contacts on the circuit board.Best of luck and thanks for the note! 1. The fix for the first diagnosis is simple, change the battery. The speedo works fine except the LCD is very dim and unreadable with out a magnifying glass. And no, when I drive it there is no speed indication. All solders look great. Sportsman 500s are made to give out quality performance. 263 61K views 4 years ago Fixing the broken AWD on the Polaris Sportsman 700 EFI. My speedometer works everyrhing, backlights and hours digital counter, only the speed counter and the digital miles counter doesnt work. Put it on the shaft and use a match so as not to get too much heat. The light will blink as a result of this. 16 Posted October 25, 2019 I have a 2000 Polaris Sportsman 500. If all goes well, the lights will turn on and you'll see the odometer displaying numbers. I was able to fix my speedo for a few bucks and an hours worth of work! Always charge the battery before using the speedometer. I like to tinker, so I carefully took off the clear plastic lens with a razor knife, took the 4 screws out and found the tiny button switch parts floating around in the case. The hardest part was getting the needle off. Seems to have worked very well.After replacing the battery and voltage regulator, the reverse switch and 4WD appear to be working properly. It's a very small piece of sheet metal, perhaps a quarter inch square. PLEASE NOTE:While I DO appreciate comments, those comments that are just vehicles to other web sites without substantial content in their own right WILL NOT be posted!If you include a link in your comment that simply points to advertisements or a commercial web page, it WILL be rejected as SPAM! I have those 3 pieces on order and went ahead and disassembled my speedometer. Polaris Speedometer Repair - Part1 Here are pics.[IMG]http://i324.photobucket.com/albums/k344/ewgoetz/Misc/2FD7EED5-E74F-4763-8140-C2DBC72CECA5_zpsgdhmegov.jpg[/IMG][URL=http://s324.photobucket.com/user/ewgoetz/media/Misc/5DB7EB40-F37F-4E8D-B7B5-5A6C5860433F_zpstcvr713v.jpg.html][IMG]http://i324.photobucket.com/albums/k344/ewgoetz/Misc/5DB7EB40-F37F-4E8D-B7B5-5A6C5860433F_zpstcvr713v.jpg[/IMG][/URL]. toys for the workbench! Any ideas? If you do figure out a non-destructive way to do this, please let me know!Best of luck! When the Zebra strip goes flaky, one usually sees that there are certain - but not all - segments/portions of the display that are affected. Being that the speedo was on my friend's '500 - and that I fixed it as shown in the pictures - I don't have it to look at anymore, except in the pictures.I've sort of lost track in what parts and pieces that you have laying around, but you may be able to transplant some bits and pieces between the two and make one working unit, provided that wire locations are very carefully noted as you disassemble, taking pictures and more importantly, notes.Since the needle on the Ebay unit reportedly moves you may be able to "marry" the two units together - just be VERY careful of the fine wires. After 5-10 minutes, Once you are satisfied that the pointer is correct, firmly push it in on the spindle as far as you noted that it had been pushed before you'd removed it. Lets look at some of the possibilities for the mishap of the speedometer. So, what can the Polaris Sportsman 500 speedometer blinking mean, and how to fix it? Founded in the mid-1950s, they came into the spotlight fairly easily in Minnesota, US. Step 2 Lock the parking brake and place the ATV into neutral. What you see in Figure 5 is a generic wiring diagram for the Polaris, one of which that we found online that shows how things are connected to each other. I have a clarification question regarding the TIP48 and the B-C-D direction relative to your fig4 picture. Wait for a 10-second period. I STRONGLY suspect that the TIP48 got so hot that it unsoldered itself and fell off the board.The most likely cause of this would have been a bad battery or flaky battery connection causing the voltage to skyrocket and the device to heat up: It is entirely possible for the device itself to get hot enough to melt solder, yet survive another day.Good find, and now that you know what kills the speedo (and the the 4WD switching) on these things! If the unit has been stored outside in the sun without a cover, it may have been degraded by a combination of the sun and heat.Finally, it may be that the voltage regulator for the computer circuitry may be have a low voltage, but just high enough to still be functional such as what can happen when an LCD digital clock/watch has a weak battery. How did you do that? However, the given were the most necessary tips for the users. How to Trouble Shoot issues on a Polaris Sportsman 500! Engine Not Starting 3. I cracked the shaft of the dial. After changing the batteries the speedometer should be in full working order. I did the suggested repairs and when I placed my 1999 polaris sportsman 500 speedometer back in, it worked as it should. Mine is a 02. Repair of the speedometer requires some knowledge of electronics and board-level electrical components. The circuit board is a bit different than the one shown above. This article will give you nitty-gritty information on all that is involved. Not sure if one bounced away or if there is only supposed to be one. Polaris EPS means Electric Power Steering system. When putting the face plate back on, remember to re-install the black push-rod that operates the button! Mark's deep understanding of various types of vehicles such as UTVs, ATVs, cars, Trucks, and lawnmowers which allows him to provide valuable insights and information. The sides of the speedometer cables are connected with clips. Thanks in advance! The speedometer/odometer works by counting the rate of pulses from the wheel sensor - there's a computer in the speedo that does this to calculate the speed and distance traveled.The ways that a speedo could differ from an old one would be:- The old (or new) one is bad- Different model/type/manufacturer- Something wrong with the wheel sensor (more pulses = faster)- Tire different size (smaller = faster)I looked to see if there could be a way to calibrate the units for speed, to compensate for different tire sizes, but Google hasn't revealed it - sorry. Hooked it to the speedometer and got nothing. I can now add a few more facts to the discussion. Having said that, I don't know where the sensor is located or what will have to turn to trigger it. As an Amazon Associate, I Earn From Qualifying Purchases. Diodes (in general) have a "band" on one end indicating the anode connection - important since they are polarity-sensitive devices: This band coincides with the "line" end of the diode symbol (e.g. Presuming that you have verified that the LCD is bad - and that it isn't something else - about the only way to get the screen is to find a donor unit somewhere: Based on the apparent number of dead speedos out there, someone on a forum should have one. Now when I do the normal bench power test the needle does not return to O and I feel no resistance to it. Everything is functioning on it. There is only one, and it must go on the left side as you look at the front of the speedometer in its normal orientation.Thanks agqain for your help Clint! So now that speedometer is trashed to say the least and i need to find a replacement. It looked as though the transistor was not fully embedded into the board, and was able to break loose with some vibration. The ECU (Engine Control Unit) is the brain of the speedometer. The LCD panel or the external diode melting can cause a big conundrum! Do you think is the same problem you had? If the odometer works and is anywhere in the ballpark, it would expect the wheel sensor to be OK.Since you have nothing to lose, check to see if the needle's spindle is cocked at an angle as it may have popped loose from the pivot at the end opposite the needle. 2001 Polaris Sportsman 500 Speedometer Problems Also, performing the diode tests on it after it was removed revealed all open circuits, and a diode test on the solder pads on the board still reproduced the climbing reading. However, some speedometers can run on dead batteries. I didn't have a 1N5245 1/2 watt, 15 volt Zener around, but I. Hello, thank you for all the information you have provided. The "speed" would be proportional to the pitch of the tone.If you don't feel completely comfortable doing this, just plug it back into the Polaris, wires hanging everywhere, and carefully drive around!I'm guessing that, perhaps, the newer speedos "lock" the pointer when the power is off - like the dashboard gauges of many cars these days? They also supply motorbikes, snowmobiles, and neighborhood electric vehicles. Then remove the speedometer module from the body. I replaced the wheel sensor but it wasn't bad. I did check eBay again today and got a NIB for $300 instead of $400, so I suppose that's my silver lining.Again, great write-up my friend and I thank you for taking time to put this together. This usually means you need to replace the whole speedometer or the IC board. I have a speedo apart and the only visual damage is to a phier Spain component, which is at the top right of the board, 3 prong with a white center, do u know the specs on that so I know which to order, I belive the numbers on the side of the component says 33 18. The Speedometer got water inside of it and it sat for a long time. it had the NO LIGHTS, NO SPEED (needle), NO HOURS (digital), and NO MILEAGE (digital)issue. The Polaris brand is a household name synonymous with four-wheelers. First manufactured in 1999, they are very powerful by horsepower and bulk suspension-shock resistance. I replaced the regulator and the AWD, speedo & reversre overide didn't work anymore. The ECM has a safety recall on it for certain models. polaris uses the speed of the quad in its calculation for the on demand 4x4. Finally got everything put back together last night. Here's another: Long story short, I tested the transistor (it was fine) and then resoldered it into board and everything works now. This means a month of use. Ordered parts you recommended but once I got into speedo I found the tp48 was correct but the other transistor and diode are surface mount, can I still install them in there place? Show more Quick & Easy Fix of Polaris Xplorer AWD - 4x4 - 4WD Hillendale Bros 4.1K views 2 years ago POLARIS AWD. . Lucky my TIP41 transistor had just came un-soldered and was laying loose in the speedo. I too was hunting around for a second one after I took it apart because the bracket and contacts on the board can accept one on each side. Kioti DK 65C. 2 Answers L Pfaff Polaris Master 11,573 Answers Gary, Faulty fuel pump sending unit. I need help to identify the possible parts to check. When removing the old components (the two transistors and the Zener diode) it may be easiest to just clip them from the board first using small, sharp diagonal-cut pliers. Using your phone or camera, take some close-up pictures of both sides of the board before you start as a possible aid in reassembly. Damaged wiring is also a concern for safety issues. Also, check if we get our speedometer and sensor back. Great informative tips on repairing a Polaris Speedometer. If it has, you may be able to put it back in place.The other thing to check would be for tiny iron filings between the moving vane (rotor) and the stationary portion of the "motor" comprising the speedometer's indicator - but it may require microsurgery to get access to this. I have the same speedo as Mathias but the only part that looks bad on mine is a black rectangle box at the top. Sportsman 500s are made to give out quality performance. However, when I opened my speedo up, the board seems slightly different than what you have pictured in figure 4. Hi there I loved this article. The rear lower control arm bolts are junk and need upgrading to Grade 8. For ease, we mention them in a brief description! polaris sportsman 500 speedometer for sale Maybe a competitive professional or even a beach tour guide. Youll notice that youre unable to put it in four-wheel drive. Since it's been about 5 years since I wrote this article, I don't recall specific details of the small pieces - but the "metal contact" that you mention wouldn't actually be a contact (the Zebra strip does that) but more likely a guide or a mechanical stiffener.If you can't find another piece (say, with a magnet) then put it together "provisionally" (e.g. But the malfunction requires you to remove and reset the speedometer. Your thoughts from here?paul.reynolds@coxinc.com. My 2001 speedo just died. Sportsman 500 with Broken Speedometer SOLVED: Fuel gauge flashes need fuel most of the time - Fixya I replaced the 3 parts plus the 470uf cap (near the edge) as it was obviously cooked. Then remove the speedometer module from the body. I have a decent soldering and hot-air rework station and could potentially attempt the repair. After reassembling, turn up the power transistor. Sorry to hear that - I (and, no doubt you!) 6 x Polaris Sportsman 500 Problems and how to Fix it! Engine Overheating 4. First off, thanks for the excellent write up, it's appreciated and helpful. Background: The only way that I can think of simulating a wheel sensor using things on-hand other than an audio signal generator would be to use a PC/laptop (running Windows) to generate an audio signal with a free program like "Audacity" - say, several minutes of a 100 Hz tone.Playing it back on a computer, feeding it into a cheap set of powered computer speakers, take the output of the computer speaker connector, disconnecting the speaker. Turns out they are only a few hours drive from where I live, so the cheapest shipping was as good as overnight.I carefully soldered one of the new surface mount transistors in place, applied 12V to the power pins andIT WORKED! The most common reason is whether AWD is getting power or not. Hello. This is an indication of the IC malfunction. Speedometer REPAIR fix 2000 Sportsman 500 Soldered it back on and its working like a champ. I haven't been able to locate a wiring diagram 2003 speedo does not have the aluminum ring looks like the lens is glued on. It worked on mine. But first, youve to plug it in temporarily and check if it works with all the other functions. Thanks for the well written procedure! It would be interesting to know if your reverse override works or if you can put it into/take it out of 4WD.If everything else works, it may be that something with the digital display has died - perhaps you can recover it by cleaning the "zebra strip" mentioned in the article and re-installing the LCD glass, but if that's all that wrong, I'd probably leave it alone. The MPSA42 is a high-voltage, low-power NPN transistor of the type typically used in video drivers for cathode-ray tubes on older TVs and suitable equivalents may be found on the small circuit board attached to the end of a CRT on a discarded television.