Polaris Ranger RZR Forum

[ThrottleOut]

I saw THIS the other day and was wondering if anyone understands exactly how this is done so I can do this to the RZR? I really like the idea of NOT having to add any external switches, just relays that will tuck up under the dash neatly and out of the elements. Their kit seems to be reasonably priced and wouldn't mind paying what they want for it but I like to know how they accomplished this before hand. Any help/info is much appreciated.

[guy48065]

I can guess at it...
The trans has a rotary switch on it that connects to a resistor pack. The digital guage reads these stepped resistances to determine where your shifter is. The kit cuts into the swich contact for Reverse and adds a relay coil to the line. Apparently (and this is what I don't understand) this doesn't affect the digital guage function. I gotta believe at a minimum that it wouldn't indicate "R" anymore. I'm leery of the long term effect of running relay coil current thru a switch that's intended only for a resistor load of several hundred ohms. Maybe a real electrical guru found that the reverse resistor value was close to the relay coil resistance and decided "why not?"

Then again I could be totally wrong...

[guy48065]

After some more head scratching I'm pretty sure the second relay is used for completing the resistor-to-ground path for the gauge.



I like this mod. I think it's a better way to go than the magnetic switch I put on my shifter. It doesn't look any easier (still involves cutting into the harness & running a couple new wires), but it makes more sense to do it this way.

[ThrottleOut]

Those are great drawings

They really help to understand how this could be done. The biggest hurdle for me was understanding the resistor pack and ground relationship. I was under the impression that the signal went to the gauge somehow from the selector switch.

The thing I like most about going this route is that you don't need to fabricate anything to make it work (which I could easily do, but someone else might not, making this the ideal choice for them).

Next question:

Where's a good source for an "off the self" DPDT relay that is waterproof?

[guy48065]

Next question:

Where's a good source for an "off the self" DPDT relay that is waterproof?

That's going to be tougher. I checked eBay and Radio Shack and neither has an inexpensive 12V DPDT sealed relay. Fortunately you only need a couple amps for the lights so you don't need a heavy duty relay. The only suggestion I can come with is to wire up a plug-in control relay like this one:


and then dip it a few times in Plasti-Dip to seal it.

A DPDT relay would be smaller and neater looking but I'm sure the original kit chose to use cube relays because of how common & cheap--but good--they are. You can get relay bases that snap together to any length.
http://www.rallylights.com/hella/Relay_Boxes_and_Fuse_Boxes.asp

[ThrottleOut]

Originally posted by want2beyounger on prcforum.com
A few of us engaged in a conversation on night last week regarding automatic back up light in this thread.

http://www.prcforum.com/viewtopic.php?t=11591

Everything we came up with made sense. Here are the wiring diagrams that guy48065 drew out



All captions are above corresponding photo. Here is what I did. First locate Resistor Pack--Under drivers seat, zip tied to the main wiring harness traveling to the rear of the machine



Gain access to the wires entering plug.



Locate Wire harness from trans to see if access is easier there. It is not easier, but it is not more difficult.



Disconnect battery



Unbolt starter solenoid for more room and move to one side



Expose a little more of the wire from the harness.



Everything is labeled



I prewired the two SP relays and labeled wires. Relays and connectors cost about $30.00 I would have preferred to go with one DP relay, but none of the suppliers I checked with had them in stock. I Checked and rechecked configuration of the wiring if the relays.



Mounted relays above ECU behind drivers set.


Note the three red wires I ran exiting the wire loom down at the main wire harness by the resistor pack. These come from the relays and are tucked neatly inside of the loom.



Cut, splice and solder the purple wire as per wiring diagram.







Tap into blue wire as per wiring diagram that runs thru the loom over the ECU



Solder and heat shrink wrap





I tapped into the 12v supply as per diagram into the red/yellow wire in the same loom as the blue wire. This wire feeds the tail lights when the key is on.







Close up the loom with new wires and splices inside. Note the ground wire with the blue connector in the background. This wire comes from the relays as per diagram.



Fasten the resistor pack back into its original location with a zip tie



Reinstall starter solenoid into original location with original bolts



Reconnect Neg. battery cable and test





All is good

[blackbart]

I gotten ALL the parts together including the relay as pictured from guy. I'm not very electrical oriented so here's my question. The relay has 8 plug connectors on the bottom, SO, which ones do I use or corresponding to the DSDP .

B O T T O M of R E L A Y numbered as below

|1 |2
|3 |4
|5 |6

_7 _8
One dummy, thanking you in advance.
Bart

[guy48065]

7 & 8 are the coil terminals. 135 is 1/2 the relay and 246 the other half. You should be able to look through the cover and see which contact is on which terminal. With no power applied to the coil one set of contacts will be 'made' or 'normally closed', with the other (normally open) contact right below the moving arm (the 'common' terminal). You want to make your connections to the normally open set of contacts.

[im4seven]

Anybody figure out how to do this on an 09?

[im4seven]

OK, just compared the 08 and 09 wiring diagrams. The 08 as you know by now has 6 wires coming out of the trans switch going into a resistor pack. The 09 appears to have the same internal switch but lists ohms for each of the switch positions. (reverse is 75 ohms) There are only 2 wires coming out of the transmission from the selector switch. They are brown w/ red tracer and white. Anybody have an idea how to make this work w/ that information? The 09 wiring diagram can be found at http://docs.extremerzr.com/docs/polarisrangerrzrs800servicemanual09.pdf