Have you cleared them and then checked for new ones after a ride ? That's a lot of codes.. Some might be old.
2006 Sportsman 500 Codes 42,41,22,45,47,47 and 51
I have an 06 Sportsman with several codes that I cannot get to clear. It starts and runs fine with the exception of an intermittent bog under acceleration. I have opened up and gone through the entire engine wiring harness, the tmap pigtail has been replaced, tried a new ECU, tested for shorts, opens and high resistance. I have 12 volts to the ECU and my 5V sensor feed is good at all of my sensors. I’ve been a tech for 30 years and nothing has stumped me like this thing has. Any help or advice would be greatly appreciated.
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I have cleared them and they come back as soon as the key is turned on. When I replaced the ECU all the codes set as soon as I started the bike, so there has to be a hard fault. I’ve gone through all of the sensor resistance checks that are listed in my repair manual. I’ve load tested all of the wires, and back probed the sensor return wires while the bike is running. I cannot find anything that would cause any of these codes to set.Have you cleared them and then checked for new ones after a ride ? That's a lot of codes.. Some might be old.
I haven't looked them up but no vehicle gets that many faults before even starting.. There won't be that many with a common earth or power I shouldn't think either.
Are you sure the ecu is correct for the bike ? Have/can you try that ecu on another bike, or borrow an ecu ?
Are you sure the ecu is correct for the bike ? Have/can you try that ecu on another bike, or borrow an ecu ?
But it runs pretty good I see.. I better go check what the codes are.. haha.
Ok, so my manuals didn't have the codes so I looked online and the problem seems fairly common for polaris(who's have guessed).. I read one reply that said they had all the symptoms and they swapped ecu and it went away, put ecu back in it returned.. faulty ecu(or wrong one).. I'd suspect ecu.
Not sure if it will work or not in this case but in some polaris models when you first put the dash into diagnostic mode it shows the software version that's in the ecu.. It might pay to put the old ecu in and try to read it's software version and check it's the same as the new one.. Other than that I'd be trying to test the ecu in another bike or borrow another ecu to try.
You'll know what the final line in the diagnostic chart always is.. "Try a known good unit".
Not sure if it will work or not in this case but in some polaris models when you first put the dash into diagnostic mode it shows the software version that's in the ecu.. It might pay to put the old ecu in and try to read it's software version and check it's the same as the new one.. Other than that I'd be trying to test the ecu in another bike or borrow another ecu to try.
You'll know what the final line in the diagnostic chart always is.. "Try a known good unit".
The ecu I put in came from the identical bike and has the same part number on it. The odds of 2 ecu’s having the exact same issues are highly unlikely. I’m wondering if the module that controls all the system voltage could be causing the issue. The codes started shortly after my stator failed and was replaced. Voltage is around 12.4V at idle, and jumps up over 14 with rpm which is normal. The battery is fairly new and is in good condition. As I said in my original post I’ve been a tech for over 30 years and specialized in electrical. But this thing makes no sense. I was hoping someone else had experienced the same issue. I’ll keep plugging away and post what fixes it.Ok, so my manuals didn't have the codes so I looked online and the problem seems fairly common for polaris(who's have guessed).. I read one reply that said they had all the symptoms and they swapped ecu and it went away, put ecu back in it returned.. faulty ecu(or wrong one).. I'd suspect ecu.
Not sure if it will work or not in this case but in some polaris models when you first put the dash into diagnostic mode it shows the software version that's in the ecu.. It might pay to put the old ecu in and try to read it's software version and check it's the same as the new one.. Other than that I'd be trying to test the ecu in another bike or borrow another ecu to try.
You'll know what the final line in the diagnostic chart always is.. "Try a known good unit".
The power module could likely cause it for sure.. You know what they say when there's a lot of fault codes or none at all, check all the earths and all the powers into the ecu..
I agree that the odds of getting two ecu with the same symptoms seems low, but this does sound like a common problem, so unless you saw the other bike running, or can swap your ecu to it, I wouldn't rule it out yet.
There is one good aspect.. it's not intermittent.
I've been a mech for a long time and I've always been the workshop sparky and diagnosis guy, (and they tell me I'm good at it), but like you, these things can be difficult and frustrating. Keep us posted and feel free to run any ideas past us..
I agree that the odds of getting two ecu with the same symptoms seems low, but this does sound like a common problem, so unless you saw the other bike running, or can swap your ecu to it, I wouldn't rule it out yet.
There is one good aspect.. it's not intermittent.
I've been a mech for a long time and I've always been the workshop sparky and diagnosis guy, (and they tell me I'm good at it), but like you, these things can be difficult and frustrating. Keep us posted and feel free to run any ideas past us..
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