The Polaris RZR side-by-side was first launched in 2007. It was a near-instant success with off-road enthusiasts, and even some military units around the globe. But like any motorized vehicle, the RZR can suffer issues from time to time, one such issue being a failed gear indicator.
When your RZR’s gear indicator fails (showing the wrong gear or a “—” in place of the gear), the fix can be easy or a bit tricky. The most common reason RZR gear indicators fail is due to muddied, wet, or loose wiring at the transmission pack.
With this article, I aim to get your RZR’s gear indicator back to fully functional condition. I’ll start with easy solutions and work my way into stuff that’s a little more difficult (though not much). Let’s dive in.
1. Check That the Instrument Cluster Is Plugged In Correctly
You likely do a lot of bumping and bouncing around in your RZR. It only makes sense that some wiring could jiggle loose from time to time.
Reach under the dash and ensure that the instrument cluster hasn’t come partially dislodged from the circuit. You can even pop out the wiring harness and plug it back in to re-establish a clean connection.
Did that work? Nope? On to step 2…
2. Make Sure the Transmission Wire Connections Are Clean and Tight
As mentioned, transmission wiring is the biggest culprit for a quirky gear indicator. The RZR’s transmission is located in back of the vehicle, between the rear tires.
On the right-hand side of the transmission, you’ll find the gear position switch (the switch looks like a black donut mounted on the tranny). The wires connected to the switch should be clean and firmly inserted.
Disconnect the wiring and make sure the terminals are not rusty or dirty. To protect them from the elements, you can use dielectric grease on the terminals. Connect the wiring, fire up your RAZR, and see if your issue is resolved (source).
If not, make sure the wiring—or the terminal—isn’t physically damaged. If one or both are damaged, replacing them is a good idea, even if they are not actually causing your gear indicator problems.
3. Clean or Replace the Transmission Resistor Pack
Just as off-roading in a Polaris RZR can get wiring dirty, it can also get the vehicle’s transmission resistor pack dirty. You’ll find these resistor packs under the driver’s seat or directly behind it. The head is shaped somewhat like that of an HDMI cable and has 6 connector strips on it.
It is very easy for mud to build up on these packs while you’re tearing through rough terrain in your side-by-side. Mud and moisture will prohibit the resistor’s ability to regulate your transmission’s speed and gear changes. And indeed, a faulty resistor pack can also cause errors to occur on a RZR’s gear indicator.
For a more pictorial idea of what I mean, see this diagram (source).
4. Replace the Speed Sensor
You may have never heard of a vehicle speed sensor before, but it’s vital to your RZR’s transmission. These sensors communicate with an engine control module to regulate ignition timing and transmission. (source).
You may not need to replace the speed sensor. To find out if it’s failing, you can conduct a simple test.
You’ll find the speed sensor right on the transmission case cover. It’s a black piece of plastic and wiring attached to all that silver metal. Approach the sensor from the left-hand wheel well.
Before you begin the test, you’ll need two things: A static timing light harness and a Hall sensor probe harness.
Here’s how to run the test (source):
- Disconnect the wire harness and remove the sensor from the transmission housing
- Using the Hall sensor probe harness, connect the wires to the static timing light harness
- Move a screwdriver back and forth in front of the sensor tip
- The 9V battery on the static light harness should make the LED flash
- If the LED does not flash, the speed sensor needs to be replaced
The above steps may look complex at first glance, but they’re honestly not. Nor is replacing the speed sensor (you were just able to pop it off quite easily).
If the speed sensor is good—or if you replaced it and the gear indicator still doesn’t work—it’s time to look at your RZR in diagnostic mode.
5. Check the Resistance Value in Diagnostic Mode
Every Polaris RZR comes with a diagnostic mode that you can access right from the instrument cluster. It displays a kind of checklist so the owner (that’s you) can track down issues in places like the charging system, engine RPM, all-wheel drive, and routine maintenance reminders (source).
Diagnostic mode will also tell you, for each gear, if there are problems with the transmission. To enter the RZR diagnostic mode, follow these steps:
- Switch off the car for around 12 seconds.
- Put your transmission in neutral mode.
- Set the brake if your car has a parking brake.
- Turn the key in the ignition while long-pressing the Mode button.
- Take your hand off the Mode button once the lights turn on.
Now switch over to the gear circuit diagnostic screen, because here we’re going to see whether or not each gear has the correct resistance value in ohms.
Wondering what those values are? Have a look:
- High—620 Ω
- Low—300 Ω
- Neu—160 Ω
- Rev—75 Ω
- Park—24 Ω
Should the gear circuit diagnostic screen read high or low for any of these shift positions, it may be the reason for your gear indicator issue.
From here, you can go back to the transmission and test its wiring for the correct ohms. However, the diagnostic screen is intended for informational purposes only. If you really can’t get to the bottom of your gear indicator troubles, don’t be too proud to contact a certified Polaris RZR mechanic.
Gear slipping is another common problem you may face with your Polaris RZR. Click on the link to learn what to do when the gear keeps slipping.
Conclusion
It is not uncommon for Polaris RZR gear indicators to malfunction. Rarely, however, is the issue so serious that it needs professional intervention. Most times, you can fix things yourself right in your own garage. The instructions provided in this article should help you get back to romping in your RZR in fast order.