Machine:

2006 Polaris Sportsman 500 H.O.

I have had a handful of problems out of my machine, and now that work is starting to slow down a little, I am trying to get all of them fixed, and my regular maintenance out of the way within the next few weeks.

A little background on my problem:

Starts up, and runs fine. Idle's fine. Take it out and ride, give it some throttle, and the machine just dies, no puttering or anything. I still have power to my unit, I even had enough power to run the lights, and operate the winch. I had to wait a few minutes before it would fire up again. I have heard vapor lock being a possible culprit, but after it died one time, I loosened the screw and gas came out of the drain of the bowl.

I am pulling all my breather lines, and cleaning my air box as it was a little dirty, replacing filter and prefilter, cleaning the carb, replaced spark plug (which the old one was moist, I think it was just gas or something on it, it wasn't really the texture of oil in my opinion, but I do not know) and unfortunantly I am replacing the ignition coil because it ripped apart on my when I was pulling it from my spark plug. With all that being done, I am hoping that one of them was the problem, but worst case scenario and it still does not run correctly, I would like to figure some other things out. I have been told that sometimes relays or fuses go bad. Problem is, I can not find my fuses or relays, unless they are tucked away where I can not see them very well. I have looked up front under my basket, under the hood, and even under my back seat with no luck finding relays or fuses. I am guessing that if they are a snake, they would have bit me by now, but I still can't locate them and people keep saying to find them and check them. If anybody can offer any help in finding them, and telling me what the pieces pictured below are, I would appreciate it very much.

 

There are no fuses or breakers on this model...
They have a Sure Power Module box located under the front high beam headlight mounted on the frame.......If you take the plastic clip in inset off there you can see it a little bit ,but I take the front rack off to change it.

They have two solid state circuit breakers in there and will shut down for protection if needed.
I am on my third one now with my 2006 Sp 450
Both were covered ,no charge to me........
...Caper..........

 

Okay, now I feel better that I am not just overlooking it. Are you referring to part number 13 in the diagram below?

 

call the dealer w/ your vin" to see if your bike was under the recall for the ecm.

 

I just took it to the dealer about 2 months ago and the ECM was replaced. Still died out on me after having that done. I was really hoping that was the problem, but it wasn't. I am waiting on a new coil, and wire to come in this week since mine decided to snap in half on me the other day, hopefully get my carb all re-assembled and get my radiator cleaned and everything back together this Sunday and see if any of that helps. I have been meaning to take my battery up and get tested as it has not been replaced since I bought the machine a few years back. I really think the battery may be going out because when I am riding, my battery light flashes, but if I hit something that draws power, it stops flashing, then starts flashing a few minutes later. Sound like a bad battery, or a regulator? I still have enough power to run my winch and everything when it is flashing.

 

I think it looks like part # 11 above........It is the Sure Power Module Box
Factory one on mine was Black in colour(Made in China) and the replacement was silver(U.S.A. made),Still made by Sure Power Industries

 

I just had that replaced on mine, that is the ECM. It was replaced under recall.