OK all, here we go...I installed the new pins that Berniep gave me the info on...and the Instrument Cluster turn signal indicators now function as they should!! The whole project took me about an hour to complete and that included the time to write down the steps in the following description.
Here we go:
Remove the Driver’s Seat and place a soft towel or something like it on the battery cover for a place to set tools and parts.
Remove the upper Tilt Cylinder bolt. Takes a 4mm allen and 10mm end wrench.
While holding the steering wheel up, place a pry bar or large screwdriver between the Tilt Cylinder and Steering Column and pry the Tilt Cylinder out of the bracket on the Steering Column. Just let the Tilt Cylinder hang by the lower bolt.
I set a jack stand adjusted to 15” tall and placed a soft cloth on top of that, and let the steering wheel rest on it. Thus protecting the Steering Wheel.
With the Steering Wheel resting on the jack stand its easy to see the Instrument Cluster Visor and the Instrument Cluster Plug on the back of the Cluster.
Remove the Instrument Cluster Visor by first pulling out at the bottom outside corners to disengage the clips, then lift off the top clips and set the Visor aside.
Now to unplug the Instrument Cluster wiring harness. Take a minute to look at the backside of the cluster and you will see the grey plug as shown in the pic below.
The clip is on the bottom. As shown in the pic press in on the top of the clip to release. To be honest, I had to use a long thin screwdriver behind the lower end of the clip to get it to pop loose from the Instrument Cluster. Take your time and be careful. I wasn’t the first time around, and learned the only way to get a replacement plug is to buy an entire wiring harness for the General. That was a bit over $800! But now I have the rest of it if I ever need it. (I hope not!)
http://www.polarisgeneralforum.com/forum/attachment.php?attachmentid=35394&thumb=1
Now go back to the information Berniep provided on how to disassemble the plug. And with the proper Mouser pins in hand…and a pin crimping tool or a set of small needle nose pliers…
As shown in the pic below:
Slide the grey portion of the plug up the wiring harness far enough to be able to slide the orange rubber section up the wiring harness and expose the white piece of the plug.
As you can see there is a yellow wire at both ends of the plug and there are two open wiring holes to the right of the, whew, left hand yellow wire. These two open ports are for the turn signal indicator wires. The two ports are pin 6 and pin 7.
Pin 7 is the Right turn signal and I chose to use Red wire…Red for Right.
Pin 6 the Left turn signal and I chose to use Green wire.
http://www.polarisgeneralforum.com/forum/attachment.php?attachmentid=35402&thumb=1
Strip the insulation from just a bit over ¼” of the wires for the Turn Signal Indicator inputs. A note here. As I wired the turn signal kit in, I ran a Red hot wire from the right front turn signal to the instrument cluster and a Green hot wire from the left front turn signal to the instrument cluster. These two wires are the ones to crimp the new Mouser pins onto.
http://www.polarisgeneralforum.com/forum/attachment.php?attachmentid=35426&thumb=1
When you have the pins securely crimped onto the Red and Green wires. Insert them, one at a time, through the grey section, through the orange rubber section as shown in the pic below:
http://www.polarisgeneralforum.com/forum/attachment.php?attachmentid=35418&thumb=1
Now carefully insert the Green wire through the #6 pin opening and the Red wire through the #7 pin opening and push them in until you hear the pin “click” as it locks into place. I used a small set of needle nose pliers to hold the wire as I pushed the pins through the white section until they “clicked” into place.
Now is the time to replace the translucent grey piece of the plug over the pins. One side of the piece as a rectangular engagement piece on it. This side goes over the exposed pins. You can sorta see that in the pic below. The rectangular piece is on the same side of the white piece as the wires.
http://www.polarisgeneralforum.com/forum/attachment.php?attachmentid=35410&thumb=1
Push the translucent grey piece onto the white piece until the two clips engage. There I a pic of this earlier in this post.
Now work the orange rubber piece down over the white piece until fully seated.
Now work the grey plug piece down over the orange rubber piece until the clips on the top of the white piece click into place in the grey piece.
Now insert the plug into the Instrument Cluster until the clip engages. And you’re done.
If I could figure out how to upload a short video, it would show the left, then right, then emergency Instrument Cluster indicators flashing as they should!!
Yup all of them work as they should!! A big Shout Out to Berniep for his video and information on which pins to order!!!
Pirate
