Ok, no breakers. There is a fusible link by the battery which shows power. Maybe you can help. I am checking for power in various locations. At the switch I cannot get any power off any wire. At the key, when the key is in off position and the switch in off position I get power on the two orange wires. Very dim light from the tester. By the ecm there is constant power off of two of the wires. Is this correct? Would this indicate if either the switch or key ignition would be bad?

 

You can always just unplug the switch and ohm it out. Switches can short out same as an ecm can.Plus check the connections and wiring leading from the left control switch. I've had to replace these also if problems were in the switch itself. Think this is where a wiring schematic and trouble shooting guide would help if you don't have a manual.2004 Polaris Sportsman 500 Service Manual PDF Download

 

Quick question. Any idea if an ecm from sportsman 600/700 would work on my 500? The numbers are different. The 600 is 4011044 and the 500 is 2203348. I found a killer deal. They look exactly the same, plugs and dimension

 

Nope different part# as the 4011044 on the 600 updates to 2203350. #24 Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

Thanks. I am getting power to the ecm. I am checking at the switch and ignition and I only get a little power when switch and key are in off position(very dim light from tester). I am not sure which wires should show power. Ecm, 2 red wires have power. Any suggestion how else to test to determine if the ecm is definitely bad?

 

One of the symptoms of a bad ecm other than the obvious no charging or intermittent fan operation is that you can have voltage into the ecm,but low voltage through it to the ignition switch,etc.Think you need to break down and get the 2203348 ecm if you can't track the problem down to the switches or any wiring shorts causing the problem.Like I mentioned I replaced a bunch of USA made modules that did the same thing as the Chinese ones did.Several machines ended up with three ecms or more including the original. Several members on the forum have gone through the same thing.

 

Thank you very much. I will do that. I noticed the wiring harness on the newer model ecm looks a little different. I guess all of it should mate up correctly. The plugs look different. Am I correct by saying this.

 

Yes the 2203348 comes as a kit with all harnesses needed.

 

Great. I will buy the ecm in the upcoming days. I will post my results

 

It has been quite some time since I have been on here. I have changed the ecm and the ignition switch. Same results, no power.