I have a Polaris 550 Sportsman EPS 2012. Totally dead I replaced the battery it was expanded on three sides. the machine has never failed to start and as long as I have had it it has never had a dead battery. I bought it used and have had it since early 2013
I had the orange light on the left side of my display come on for a short time. I got it home and checked everything out and nothing was wrong that I could find out. All fluids were ok and nothing seemed broken. Nothing burnt.
I took it plowing snow the next day and the orange light came on for a short time but went off and stayed off. I shut it off and tried to start it but could not the starter only clicked as if it had a dead battery or low voltage. No warning display lights came on and everything seems to be ok. I charged the battery some and it started but sounded sluggish. It ran for 6-7 seconds I turned on the lights and the bulb blew. I found a 10a fuse that was blown. With a good battery I have power to all fuses but my display panel does not light up. My snowplow wench does not have power to it unless the key is on. I tried moving my shifter and brake to for my safety start and nothing. To me it points to the control module beside my fuse box. I do not have a repair manual yet but will order one. So I am at a loss to as where to start? So I am asking for some help. Firswt time on this site so maybe to much information or not enough? MntMnroy

 

I'd check the fuse block itself for any wiring shorts leading into it,could be the cause of the no display. Plus don't over look wiring shorts under the headlight pod a and main harness that does a lot of pulling and stretching. It blew a fuse for a reason. If you can track down the problem and get it running,check voltage back to the battery. If more than 14.5 volts a faulty regulator could be overcharging causing problems also. Could be the reason for the old battery case expanding from too much voltage and heat.

 

Could you tell me the usage for the 10 a fuse . It says unswitch?? What about the ECM module. that would kill everything. I have power to it but nothing out on any wires. Just thinking or over thinking at this stage.

 

I'll play with it tomorrow.Idaho.lower panhandle

 

This can help you if you don't have a manual. Does have a few wiring checks that you can do at home along with the wiring schematic. If you can't find the problem then Digital Wrench probably can.YEAR Polaris TEMPLATE Service Manual PDF Download

 

OPT I still cannot get power to anything. I keep blowing the unswitch 10 a fuse. I checked all plugs and connections. I'll need to get a better test meter to check ohms on things. I am looking at the main item the ecm module. Is there anyway to test it other than taking it out completely and hooking it up to a diagnostic test computer. I have looked at 75% of the wiring and no shorted wire that I could find. I have thought about putting in a bigger fuse but then I might burn something else up? I checked the power on the fuse box. I have power to the efi and eps fuses my unswitch has power but when I turn the key on it blows I do not have power to the power side of the fuses for the Lights, Drive Accessory fuses I think the unswitch controls the relay to operate the rest of the relays that would give me power to them??
The Service Manual online has helped me thank you.

 

Don't install larger fuses! The cheap manual I listed has a few checks on the modules. Without it you're just guessing.

 

As a correction I do not have power to the ECM module. Wrong wire. I have a frustrating problem.

 

Sorry did,'t read the part that you have the manual. If it blows when you turn the key on,start at the ignition switch wiring. Still sounds like you have a direct short. Could be the switch wiring or wiring under the front panel. Electrical checks are a pain,but you have to take it slow.

 

I pulled the wires from the ignition switch and tested the switch it is good. I'll take ecm module completely off tomorrow so I can look at the pins better and may get a better connection for testing. One wire at a time. I'll disconnect my module and replace my fuse if it blows then my module should be good and my short is elsewhere.