2004.5 Sportsman 500 H.O. 4x4 Has been turning itself on and off randomly. Speedo will light up/turn on and all accessories have power .

I have replaced the ECM with the updated version due to fan running constantly, fixed that. Replaced the hall effect sensor due to speedo needle not moving.

Thought I had everything fixed, but then the speedo started to turn on/light up randomly without the key in or ignition turned on. Like it has bypassed the ignition and kill switch.

Mechanic said the Speedo was probably the issue, so replaced it with a new unit and problem still exists. Don't even need to have the key in it! The kill switch on the left handle bar does not shut it down either. I checked and cleaned the connections at the kill switch but still does it.

I have no idea where to go from here, unless some else has experienced this problem.

 

I have installed a battery cut off switch as a temporary fix so my battery doesn't go dead. Otherwise it runs fine.

 

This does sound like a ghost or gremlins in the machine. Normally I'd say the solenoid has shorted out as I've had them do this and had to pull the battery leads to get them to stop from turning the engine over,but not one where the lights come on with no key in the ignition. Think you need to do some wire tracing starting at the ignition switch wiring,plus check out the switch itself. If you don't have the wiring schematic here's a cheap manual that can possibly help.2005 Polaris Sportsman 500 Service Manual PDF Download Plus knowing these ecm modules as I do,wouldn't put it past that even the new one could be faulty. Had one poster earlier that replied that his fan ran over night and ran the battery down. Too may circuit breakers and too many functions this little silver box has to do. Wish they'd kept the old regulator/rectifiers instead.

 

Well, thought it was an intermittent problem but now the speedo stays on all the time and I can operate all accessories without the key on and kill switch off. I have the service manual but think this is out of my abilities, but will take a look. Maybe it would be worth it to take it to the dealer, instead of throwing money at it.

 

Probably best if you're not sure,but just my wild guess it's a shorted out ignition switch or wiring problem possibly under the head light where a lot of wiring problems happen that's powering things up. Keep us updated as to what the ghost in the machine is..

 

Unplug the key switch , if it still stays on I would think the ECM is internally shorted .

 

One other thing you could try is to unhook the battery , turn the key on to drain any residual current , turn key off and reconnect the battery and see if this " reset " cures it .

 

Found the problem, now I need more help. I replaced the kill swith but no luck. I moved down the wiring harness and found this:





The bottom end comes off the ECM, and the end with a burn hole goes to wiring harness. I found it by jiggling the connection and found that the engine would shut down as it's supposed to. Wire at right is solid red with red and white just to the left of it. I believe what is happening is one of the wires (or both) are touching each other causing a continuous circuit.


Question:
1. Where can I get a replacement plug? it is has 10 slots for each plug
2. What would have caused this?


Appreciate your help

 

My two cents it was caused by the ecm as they have been known to short out like this and some of the Chinese ones have caught fire and burnt to the ground also.The main reason for the original recall. The recall was supposed to have taken care of this,but I replaced a bunch of US made replacement Sure power modules also more than once for shorting out,but happily no fires. Several online connector places that may be able to help.Here's one you can contact,plus even some on ebay. Automotive Electrical Connectors | Multi Pin Connectors | Waytek, Inc. http://www.ebay.com/itm/2-sets-Car-Waterproof-10-Pin-Electrical-Wire-Connector-Plug-AWG-Car-Motorcycle-/251350578200?pt=LH_DefaultDomain_0&hash=item3a85a97418

 

So are you of the opinion that I should replace the ecm. I did upgrade the surepower to the newer silver one, but I don't think that plug was burned like that when I plugged it in.