Multiple Sportsman 500 problems. Please help if you can.

[xjoedirt55x]

I have been having a few problems with my machine lately. This past weekend I had a little bit of everything go wrong with it, so now that I

will have a long weekend coming up, I would like to spend some time fixing, or at least figuring out what all I need to fix and get my parts

ordered so if we have another weekend of good weather I am ready to ride.

My Machine:

2006 Polaris Sportsman 500 HO


Problem #1 - My battery warning light keeps flashing periodically while I am riding. Thinking it may just be a bad battery, or a loose

connection, I tighten all the connections, and everything is tight. I haven't had the battery checked yet, but when I get the time I plan on

running it up to auto zone and having them check it. But the only thing that is making me question the problem even more is that when the

warning light is flashing, If I hit something that draws more power such as my winch or headlights, the warning light stops flashing, then

comes back on later on.

Problem #2 - My starter does not work, but pull start works just fine. When I turn the key, all I hear is one click every time I turn the key,

so that leads me to believe that my battery has enough juice since it is a noticible single click, and not multiple clicks like it does not

have the juice to engage the starter fully. My guess is the solenoid is bad. I am going to try crossing the posts, and see if I get anything

out of it that way, then go from there.

Problem #3 - When we get to our riding spot, I started my machine to let it warm up, and it was running just fine. We get riding, and we hit a

straight away, so I open the throttle up a little bit, and maybe 300 feet or so later, my machine just dies on me. The kicker is that I still

had power to everything else. I even had enought power to run my winch, so that leads me to believe that I had more than enough power to run

the motor. I tried starting it up right away, with no luck. I let it sit for about 3 minutes, and it fired right back up. Tried running it

again, and the same thing happened. So I started trying to troubleshoot the problem, and started with my electrical connections, which all

checked out just fine. Then I pulled the air box to see the air filter, which was a little dirty, so I took it off, and ran it.... shut down

again. I know the gas that is in it is fine because it is fresh, and everybody else riding had the same gas as me, and it was just fine. So I

drained the bowl of the carb, jiggled my spark plug wire, and made sure it was tight of the plug, checked all my fluids, and everything was

just fine. Out of curiosity, I started it up, and ran it at about half throttle, and rode it around with no problems for like a half hour, so

I ran it open throttle again, and it kept running just fine. In fact I rode the rest of the day with no problems, even up some pretty nasty

steep hills. But the next morning after I cleaned it off, and unloaded it, it was doing the same thing, shutting off on me. I am guessing

maybe a dirty carb, or a bad fuel pump could possibly be the culprit?

Problem #4 - The sensor that tells my display what gear I am in does not work properly. When I am in high, it says "L", when I am in low, it

says "N", when I am in neutral, It says I am in "N", reverse "R", and park "P". I am thinking I am going to just have to replace this part all

together, really no fixing it I don't think. I really wouldn't mind this all except that my 4x4 will not engage when I am in low because the

machine thinks I am in neutral which sucks when I kinda need low if I am climbing a hill with lots of rocks.

Problem #5 - Towards the end of the day, my fan was not kicking on, and machine was overheating. I stuck my hand in, and turned the fan, and

it spun easily, so it was not clogged with mud or anything. I turned the machine off, and made sure I had good airflow to my radiator, and

even pulled the front screen off to get maximum air flow. I turned the key on, but didn't start the machine and the fan did not kick on at

all. That could possibly mean the temp. sensor, or the fan motor could be bad on it.


All of that being said, I am going to get the ECM replaced, hopefully this week and see if that solves any of these problems, but I know for a

fact I am not that lucky, so I am wanting to start eliminating some of the problems that will cost me nothing before I waste money buying

parts I do not need. I am also wondering if anybody else who had an ECM fail on them had similar problems, or know some of the symptoms of a

failing ECM. If you have any input/suggestions on any of my problems, I am all ears.


Thanks a lot. Joe

[matts27]

I'd first check that battery and your ground to the chasis. 13.2 volts should be the lowest, the charging systems on quads are very small and take a long time to recover. Battery tenders can save you much money down the long road, in my opinion. Second, how long since you rode it previously, could have a clogged main that you freed up, 3rdly, check the fuses for the fan then if you have a service manual check the resistance of the probe. Also, jump power direct to the fan to see if it runs, just as easy too, good luck, Matt

[xjoedirt55x]

Originally posted by matts27
I'd first check that battery and your ground to the chasis. 13.2 volts should be the lowest, the charging systems on quads are very small and take a long time to recover. Battery tenders can save you much money down the long road, in my opinion. Second, how long since you rode it previously, could have a clogged main that you freed up, 3rdly, check the fuses for the fan then if you have a service manual check the resistance of the probe. Also, jump power direct to the fan to see if it runs, just as easy too, good luck, Matt

Okay, I have a float charger, maybe I will put that on there from now on. It was only a week since I had last riden the quad.

What probe are you suggesting I check the resistance on? Do you mean probe the holes that the fuses go in for the fan? I would be just checking for some continuity, correct? I was just planning on directly wiring the fan to eliminate that problem. I have a hunch that some of this is the ECM that was recalled, and I will hopefully get replaced this week some time.

Thanks for the help.

[matts27]

I would unplug the fan, and jump some leads over from the battery directly to it. I would think maybe you got some dirt in the carb somehow or the ECM definetly would kill it too. Controls the ignition I'm sure, that would explain the brief cool down and then it re-fired. Not too familar with the Polaris so just shooting some ideas. Oh, correct battery voltage is 13.6 to 13.2. Anything below will signify weakness in the cell pack, 12.8 ~ 12.5 should pull in the starter I would think, maybe not crank well but at least turn it over. Running you should get 13.8~ but the charging systems are weak and meant to work in the upper rpm's typically. 3500 plus. I was just concerned about the winch but you said that real well and that's a large motor. Good luck with all, and I'd get that ECM if they're warranting it for sure. MAtt

[xjoedirt55x]

Originally posted by matts27
I would unplug the fan, and jump some leads over from the battery directly to it. I would think maybe you got some dirt in the carb somehow or the ECM definetly would kill it too. Controls the ignition I'm sure, that would explain the brief cool down and then it re-fired. Not too familar with the Polaris so just shooting some ideas. Oh, correct battery voltage is 13.6 to 13.2. Anything below will signify weakness in the cell pack, 12.8 ~ 12.5 should pull in the starter I would think, maybe not crank well but at least turn it over. Running you should get 13.8~ but the charging systems are weak and meant to work in the upper rpm's typically. 3500 plus. I was just concerned about the winch but you said that real well and that's a large motor. Good luck with all, and I'd get that ECM if they're warranting it for sure. MAtt

The thing with it dying out was it was an instant thing and not just a sluggish top end, so that makes me believe that it is not a dirty carb, but I guess it can not hurt to clean it out. Anything with the electrical system, I am going to just wait to screw with it until the ECM gets swapped out, which yes, that is covered under warranty, free of charge..... Now I just have to convince them to swap it out the same day if I pull the necessary plastics or just give me the part to do myself and not have to deal with their goofy waiting period..... oh, the joy of dealing with the stealership.