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4.7
FUEL INJECTION
4
EFI SERVICE NOTES
General Service Information
• For more convenient and accurate testing of EFI components, it is recommended dealers utilize the
Polaris Diagnostic Software (dealer only), or limited testing may be done manually using the
procedures provided.
• 80% of all EFI problems are caused by wiring harness connections. Follow a common sense
approach when diagnosing a potential EFI issue:
1. Disconnect the harness at the suspected sensor connector.
2. Inspect the connector ends for damage or contamination. If damaged, repair; if contaminated, clean. Reconnect and
check function.
3. If the problem persists, perform a sensor bench test according to the specific sensor requirements.
4. If the sensor bench tests pass, disconnect the connector at the ECM and perform a continuity check between the sensor
connector and the appropriate pin at the ECM connector (all connections for that sensor). Wiring resistance should be
less than five (5) ohms.
5. If the resistance is high (or open), a wiring harness inspection is dictated (including a thorough inspection of the ECM
connector for contamination or damage).
6. If the sensor passes and the wiring passes inspection, and reconnecting the ECM does not resolve the issue, then at that
point a known-good ECM (from another 500 EFI ATV) could be connected and tested for problem resolution.
• For the purpose of troubleshooting difficult running issues, a known-good ECM from a same-model
Polaris 500 ATV EFI system may be used without damaging system or engine components.
• Do not use dielectric grease on sealed connectors (connectors with a rubber grommet), as it may
displace the rubber seal and allow contaminants to enter the connector.
• Never attempt to service any fuel system component while engine is running or ignition switch is
turned to "on".
• USE CARE when removing or installing the ECM connector, as well as all other harness
connections on the ATV. Dirt, even in small quantities, can cause significant problems. Clean
connectors thoroughly before opening to prevent dirt from entering. Properly connect and disconnect
the ECM harness to minimize damage to the connector pins and locking mechanism.
• Do not use compressed air if the EFI system is open. Cover any parts removed and wrap any open
joints with plastic if they will remain open for any length of time. New parts should be removed from
their protective packaging just prior to installation.
• Although every precaution has been taken to prevent water intrusion failure, avoid direct water or
spray contact with system components.
• Do not disconnect or reconnect the wiring harness connector to the control unit or any individual
components with the ignition "on." This can send a damaging voltage spike through the ECM.
• Do not allow the battery cables to touch opposing terminals. When connecting battery cables attach the
positive (+) cable to positive (+) battery terminal first, followed by negative (-) cable to negative (-)
battery terminal.
• Never start the engine when the cables are loose or poorly connected to the battery terminals.
• Never disconnect battery while engine is running.
• Never use a quick-start battery charger to start the engine.
• Always unplug ECM from the wire harness before performing any welding on the ATV.