4.51
Cleanfire Fuel Injection
4
Throttle Position Sensor (TPS) Wire Harness
Routing
To ensure foreign material and water do not enter the TPS
connector, the wire harness must be pulled down in a loop
and secured tightly to the TPS housing.
NOTE: All 2012 and early-build 2013 models use a
TPS wire ha
rness with a rubber boot.
When removing the TPS, cut the tie strap before
dis
connecting the harness. After installing the TPS and
wire connector, secure the harness with tie strap as
shown.
NOTE: The TPS connectors must be clean and dry.
Blow dry
with compressed air. Do not apply
dielectric grease to terminals.
VARIABLE EXHAUST SYSTEM (VES)
Overview
The Polaris VES system uses exhaust valves
(1 valve per cylinder) to control the exhaust port height.
The v
alves are actuated by controlling cylinder pressure
with a solenoid, bellows, and a series of vent hoses.
The solenoid is powered by 12 VDC and turned on and off
b
y the engine control unit (ECU).
When the solenoid is powered (O
N), the VES vent paths
are open allowing cylinder pressure to vent to
atmosphere, and the guillotine valves remain in the closed
(down) position.
When the solenoid is OFF, the vent p
ath(s) are closed.
Cylinder gas pressure builds within the exhaust valve
housings beneath the bellows. Once the cylinder gas
pressure pushing on the bellows overcomes the spring
pressure, the bellows will inflate, lifting the guillotine
valves from the closed (down) position.
The ECU uses engine RPM and throttle position (TPS) as
t
he primary variable exhaust system solenoid control
signals. In general, the ECU will close the solenoid at
100% wide open throttle (WOT) at approximately 6500-
6900 RPM.
When troubleshooting the variable exhaust system, follow
th
ese guidelines:
• Use the recommended oil. Polaris recommends
VES
Gold Plus engine oil for maximum VES
performance.
• Never mix different brands of oil.
• Follow the recommended valve periodic
ma
intenance schedule.
• Do not use harsh abrasives or sharp tools when
cle
aning the valves. Small abrasions and nicks
can create pockets of carbon formation.
• Replace rusted/corroded springs.
• Inspect the bellows and replace if distorted,
str
etched, or torn.
• Replace the housing gasket each time the housing
is
removed from the cylinder. Do not modify the
gasket in anyway.
• Inspect the vent hoses and fittings for leaks.
Remo
ve and apply thread sealant to fittings that
appear to be leaking oil/exhaust gases.
• Verify all hose clamps are tight.
• Use a Mity Vac™ hand pump to test the solenoid
function
. The solenoid must hold pressure and not
leak when not powered. The solenoid must vent
when powered with 12VDC.
Do not plug the vent hoses or tamper with solenoid.
Severe engine damage may occur.
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