Table of Contents
TROUBLESHOOTING
BRAKE WARNING SYSTEM (INTL MODELS)
• This vehicle uses a brake monitoring system with half
plausibility check. This system uses a brake pedal
switch mounted to the pedal, and two brake pressure
switches mounted on the master cylinder.
• For this system to operate correctly. The Brake
Pressure Switch has to be activated before the Brake
Pedal Switch.
• These inputs can be monitored on Digital Wrench®. If
the brake pedal is depressed slowly, you will be able to
monitor the change in the Brake Pressure Switch
before the Brake Pedal Switch if the system is
operating correctly.
• If the Brake Pedal Switch becomes active and stays
active for more than 3 seconds before the Brake
Pressure Switch changes status, the Brake Warning
Light will be illuminated indicating a concern with the
system.
IMPORTANT
The Brake Warning Light may be illuminated giving a
false warning if the Brake Pedal Switch becomes active
but the system never builds pressure. This can be
caused by a very light brake apply or if the pedal is
depressed and the system never builds pressure.
• If the Brake warning light is active, refer toBrake
Warning System (INTL Models) page 9.21 for testing
procedures.
BRAKE WARNING SYSTEM INSPECTION
(INTL MODELS)
1. Inspect the brake hydraulic system for any concerns.
If any leaks or mechanical failures are found with the
hydraulic system, concerns need to be repaired
before proceeding.
2. Connect the vehicle to Digital Wrench® and select
the Data Item Menu.
3. Add the Brake Switch and Foot Brake Switch inputs
to the main table.
4. Slowly depress the brake pedal, and observe the
switching point of the Brake Pressure Switch and the
Brake Pedal Switch.
5. When the brake pedal is depressed the Brake
Pressure Switches will become active before the
Brake Pedal Switch.
9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual
© Copyright Polaris Industries Inc.
6. If all the switches are not changing status, check the
brake pedal (pay close attention to were the lever
triggers brake pedal switch), inspect the pedal mount
for mechanical damage, and check for free play.
NOTICE
A sticking brake pedal may also cause false brake
warning alarms.
7. The Brake Warning message could also be caused
by a failed sensor. If any of the three switches do not
change status when monitoring on Digital Wrench®.
Refer toBrake Light Switch page
Pressure Switch testing. Refer toBrake Pedal Switch
Inspection page 9.21 for Brake Pedal Switch testing.
8. If any of the three switches fail the testing procedure,
check the electrical circuit for the sensor that has
failed. It is possible that there could be a concern with
the circuit. If a circuit concern is found, repair or
replace as necessary.
9. If the electrical circuit passes testing the failed switch
will require replacement.
10. If the concern is still present after previous testing has
passed, suspect there is a fault within the ECU.
BRAKE PEDAL SWITCH INSPECTION
The Brake Pedal Switch is mounted near the Brake
Pedal Assembly. When the brake pedal is depressed this
switch will turn from active to inactive. This can be
monitored using Digital Wrench ®. If the status does not
switch when depressed, proceed with further testing.
1. Disconnect electrical connector from sensor.
2. Inspect sensor and connector for moisture or
corrosion. If moisture or corrosion is found, clean first
and re check.
3. With connector disconnected, check resistance
across pins on the sensor. When switch is closed
(brake pedal not depressed) resistance should be
less than 0.5 ohms. With switch open (brake pedal
depressed) resistance should show an open (OL).
4. If the sensor test fails, resistance is not within
specification; the sensor should be replaced.
5. If the sensor test passes, resistance is within
specification, inspect the circuit for correct operation.
If there is a concern found with the circuit repair and
recheck operation.
6. If the concern is still present, it is possible that there
may be a concern with the ECU.
BRAKE SYSTEM
for Brake
9
9.21
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Troubleshooting
