Hey everybody, I'm new here. I'm working on a 2005 Polaris Sportsman 800 EFi for a friend. He told me he drove it into his garage and the next day it wouldn't start. We trailered it to my house and I currently have it pretty torn apart.
Here's the deal...
It will crank over fine but not start. Won't start on starting fluid either. I pulled a spark plug and confirmed there's no spark. Checked for power to the coils and don't have anything on the middle terminal. Should be 12v.
I also have no injector pulse, no power, not clicking.
Also, no power to the fuel pump.
-----Will not flash codes. Does not even display "WAIT" or anything. I've probably tried a hundred times.-----
I traced everything back to where it gets power from.
Through splice #2 to the power relay.
Swapped relays with the fan relay. Realized that power flows out of the fan relay to the power relay. I tested both relays separately and confirmed both are good and put them back. I have power coming into both relays where it should, fuses are good, power flowing in and out of them as it should, 20A circuit breaker is ok.
I figured out that the ECM controls the ground connection which allows the relay to activate and send power where I need it. Currently the ECM will not ground the relays. I obviously can't see what the ECM isn't seeing so I started checking sensors that could prevent the ECM from doing it's job.
Crank sensor reads 580 ohms which is well within the 560 ohms +/- 10%.
Checked the TPS next, not reading anything. From what I understand, one wire provides a 5v reference signal from the ECM which is required to get a reading. I do not have 5v coming into any of the 3 wires from the ECM, nor at the ECM connector.
Everything I've read says that the engine should run even if the T-Bap or temp sensor are bad, maybe not well, but shouldn't kill power, so I haven't tried checking those.
Checked the kill switch, according to the wiring diagram, should have continuity through the switch in "Off" no continuity in "On." In which case mine is ok.
Checked ETC switch, also good. No continuity through it, per the service manual.
Is there anything else I could be overlooking? Or is it time to send it to the dealer? I suspect a bad ECM, but apparently they are not a common failure on this year model. I wish I had a known good ecm to throw in and see if it fixes it. I hate to tell my friend that I spent 3 nights tearing this apart for nothing.
Another buddy of mine is a former (polaris/can-am/something else) technician, but he went to work for a new company and isn't much help. He keeps telling me to check the PDM behind the front grille, saying it's a common failure. I think he's talking about the regulator/rectifier on this model which shouldn't have anything to do with this problem. This model does not have a pdm that distributes power like previous models.
Anything I'm missing here, any common problems that haven't had threads on them? I think I've read 50 threads trying to find something I've overlooked.
