How to make your own Ficht EMM Communications cables (2872454 & PW-45776 equivalent)

[K447]

The Polaris Digital Wrench (Windows) and PODIAG (DOS) diagnostic software uses the RS-232 serial port on your laptop to communicate with the EMM module in the Ficht PWC.

Polaris used two different connector types for the PWC wiring harness. From 1999-2001, the EMM wiring harness uses 4-pin Deutsch connectors where the laptop must connect.

2002-2004 Ficht machines use 4-pin WeatherPack type connectors where the laptop connects.

The original Polaris 2872454 cable came with a 9-pin DB-9S connector for the laptop end, and Deutsch DT04-4P and DT06-4S connectors on the PWC end.

When they changed to WeatherPack 4-pin male and female square connectors on the 2002-2004 models, Polaris issued an adapter cable PW-45776, which converted the communication cable's Deutsch connectors to WeatherPack.

While this does work, it seems rather clunky, with the unused connectors flopping around.

Attached are wiring diagrams for building separate Ficht EMM Communications Cables for the Deutsch and WeatherPack versions of the Polaris Ficht PWC. These cables are electrically the same as the Polaris original cables.

WeatherPack connectors are sometimes called Packard connectors, or WeatherPack P.E.D (Packard Electrical Devices), or Delphi Weather-Pack, or WeatherPak.

Weather-Pack 4F (Delphi 12015798 )
Weather-Pack 4M (Delphi 12015024) clip-slot
Note: Either 20-18 gauge or 16-14 gauge pins will work. I prefer the thicker wire for durability.

Wire colors do not matter, just be sure you get the pin connections correct on each connector. The 3 wire flexible cable should be several feet long, enough to allow you to position the laptop safely nearby the PWC.

Do not make the cable excessively long, as electrical interference can cause problems in long cables. Keep the cable well under ten feet total length.

One source for the 9-pin connector and cable is to buy a six foot 9-pin serial cable with a female connector on at least one end. Cut the other end off, use your ohm-meter to find the wires for each pin, and join them per the diagram.


The single flexible wire between the two Deutsch or two WeatherPack connectors only needs to be a few inches long. 12 inches would be plenty of length.

Note: Additional information can be found here;
How to make the Ficht EMM Service Power jumper (PN 2872456)
How to read Polaris Ficht EMM trouble codes without special software or a computer

[K447]

First two photos are the single wire connection in the Polaris Deutsch type 2872454 communications cable (continuing from the previous post).

For reference, the next photos are the PW-45776 adapter cable, which is used with an original Polaris 2872454 Communications cable when connecting to a WeatherPack equipped 2002-2004 fuel injected Polaris PWC.

[steelroe]

this is a very useful post.
I am a little confused in relation to the single wire connector. What is this for?

[K447]

...I am a little confused in relation to the single wire connector. What is this for?

The single White/Red wire loop connector is to allow the 45 volt power supply to be isolated from the EMM and injector system, which is useful for some diagnostics

[pose]

hello

I want to know if the diagnostic cable is the same for Hydrospace S4 ?

Does Hydrospace use the same weather pack 4 connector??

thanks

Edit: Hydrospace engine is Weber, not Ficht

[DuffBeer4U]

Cheap place for Weather Pak connectors is Spectro Wire and Cable
Shipping is UPS, which can be a little pricey if your only buying 1 or 2.

I recommend buying the connectors with 10 inches of wire, makes things a lot easier.

http://www.spectrowireandcable.com/c/Weather-pak-connectors/Weather-pak-connectors.html

Spectro Wire and Cable Inc.
PO Box 6297
2208 Pole Road
Moore, OK
USA 73153
1-800-255-6371

https://www.spectrowireandcable.com

[sr240]

so how do you read the codes is there a program?

[K447]

so how do you read the codes is there a program?

Re-read the first post, last line of text

Simple LED tool...

[gogregerson]

Does anyone know where I can get a free download of Digital Wrench?

[xsantia]

Hi! I were made cables like in the pictures, but can't connect to EMM, what is wrong, com ports propertly, but no connection what is connection need to make ,

more information please, sorry,but it is not understood for me.

[K447]

Hi! I were made cables like in the pictures, but can't connect to EMM, what is wrong, com ports propertly, but no connection what is connection need to make ,

more information please, sorry,but it is not understood for me.

The communication cable is only useful if you have access to the Polaris diagnostic software.

The jumper wire and LED tool are used without a computer.

[xsantia]

Ok, i,m understend it, and have podiag software , have pc with rs232 port, and cables like in the picture, but it can't connect to EMM, i want to see and replace number of ingector in the EMM,and check, what is errors were ,when i see check engine ...., help me connect the cables in to the EMM rite...Engine is work propertly now, with out problem 67mile.... it nice,but i want check it..

[K447]

Ok, i,m understend it, and have podiag software , have pc with rs232 port, and cables like in the picture, but it can't connect to EMM, i want to see and replace number of ingector in the EMM,and check, what is errors were ,when i see check engine ...., help me connect the cables in to the EMM rite...Engine is work propertly now, with out problem 67mile.... it nice,but i want check it..

You also have the Service Power Jumper in place to provide power to the EMM - correct? This is the jumper that plugs into the 8-pin wire harness connector that is removed from the EMM.

Can you post some photos of how you have everything connected?

[xsantia]

Ok, i must made photos,and place it here, it take time, so my MSX now in the fiberglass fixing

[urugol]

I recently made my own cables and found that Cat-6 spec (as used on ethernet networks) works perfectly well also. My plan is to splice the Cat-6 into the existing harness and install a service port inside the glovebox compartment (rj45). The idea is to run diagnostics without having to lift the seat, more importantly to run the diagnostics under load. The only issue I can see is possibly with the service jumper connection. I'm thinking that I could run a switch next to the service port to close the jumper but leaving it plugged into the emm at the same time may have some unwanted side affects or I could extened that part of the harness into the glove compartment for easy plugging.

I wonder if anyone has run a similar setup before. The netbook I am using would be secured with velcro on the glove box lid, its not a bad size for it.