We need to know the year and model and confirm it is EFI.

It could be a relay has gone bad but you definitely need a factory manual with a wiring diagram. The pump is always grounded so somehow the hot wire to the pump, which should have power only when the key is on, has crossed paths with an unswitched hot wire, either physically or because of a bad relay.

Let us know the year and model for a more definite answer.

Stew

 

It's a 2007 Sportsman 500 EFI, I just bought it from salvage. I have the service manual for it.
Worked on quad all day with son, emptied gas tank, pulled pump out of tank, cleaned sock and fuel pump still does whining/running noise even though key shut off. Nothing shows on speedometer display.
Don't know if this pump running continuous will damage my atv or not. Almost thinking of putting a toggle switch on some wire since unhooking battery is painful each time.
Going to work on atv tomorrow morning again, any help is appreciated.
Not aware of any relay either ?

 

My bad. You have Solid State Circuit Breakers (SSCB) instead of relays and fuses. Your pump gets its power through the red wire with the dark green stripe coming out of SSCB 2. There are no other junctions or splices between the fuel pump plug and the SSCB, so the possibility of wires crossing is slim. SSCB 2 is integrated into what is called the Power Distribution Module (the box with fins at the top of and just forward of the radiator). I suspect the problem is with the PDM but only a dealer can tell you for sure. On the parts diagram it is called the ECM. Part number 4011517. As much as the PDM costs, I would get the dealer to verify it's the problem. I hope I'm wrong and it is a cheaper fix for you.

Stew

 

Thanks for quick reply. Atv was from salvage site and maybe sunk, so yea it could be that with water. It's the only thing wrong, the pump keeps running and running after key shut off.
-Could I get away with fix, put toggle switch on the red/green wire and stop pump once it starts or before I park it after riding ?
-Have you ever heard on anyone opening up that ECM to clean wires, solder, etc ?
I'll go trace that wire right now this morning and tell you what I find.....
thank you again,

 

if the ecm is like most other manufactures its completely sealed with a epoxy..no way if getting it open

 

It's a shame it doesn't. I have more testing to do to see if it's that for sure.thanks for info.

 

Never heard opening an ecm up but you could be the first. The pump runs continuously when the engine is running. If the machine works ok otherwise, you should be fine using a toggle switch for the pump until you can fix the real problem.

Stew

 

Would be a good theft preventionmethod too. Perp would not know about switch and machine would not start.

 

Good idea!

 

Great ideas guys, thanks.
Update:
Took that PDM aluminum box wires off, there was water !
Took PDM off the quad and wanted to get to root of problem, so..yes...took it totally apart piece by piece. After I took the back lid off, there was water and sludge crap. Continued to dissect the entire thing, then took it's guts out. Took my time and cleaned all/dried then cleaned every contact plus verified all with magnifying glass then now have a fan on board and tomorrow in rice or contact cleaner....have to research which is best to dry ?
Just totally killing me to hook it back up and try but waiting 3 days to ensure board/guts well dried.
I took step by step pictures, so it can help others on this site since this will work !

 

Bury it in rice in a closed container. I've saved 2 cell phones that way.

Stew

 

Update, it's repaired !!!!
I buried it in rice container, then bought contact spray and sprayed the board. Cleaned connections with scrub pad. Put dielectric grease on fittings, then sprayed the inside of both plugs for pdm. Then sealed the pdm with waterproof caulking.
I am glad to say, she purrs like a kitten ! and the pump no longer runs when the key is on off.
Being able to open up pdm saved me, wasn't scared to dissect it apart, it had water and so did both plug ins. I hope I can help others with same problems. I am new here, so will try to figure out way to post my pics of repair for all others.
I may still put toggle switch anyways for security if going to derbys, restaurants, etc
Thank you to all who helped me revive my quad, saved me from buying new pdm,
Mike

 

Awesome! I'm glad you fixed it yourself and so cheaply too. When you said there was water inside I was sure the circuits would be fried. I guess not.

You will love the machine. You said it was salvaged. Is there more to fix or is that it?

Most people use photobucket to upload the pictures and then link to them there.

Looking forward to your pictures of the fix and the first ride report!

Cheers,
Stew

 

Thanks,
Yea, have to fix up and polish all scratched plastics, change all fluids (trans, front dif, already did engine oil).
Need used parts:
Seat ripped, need Polaris seat cover (buy new)
Need right hand side black panel
Front top storage compartment lid
Newer tires
Buy new black rims or try to paint my silver ones black....
Have been looking on Ebay and posted on local website but absolutely cannot find any used parts so far,
May have to buy new.

 

Beware of Serios Risk of Gas Fire if you use Toggle Switch approach

The EFI SPortsmans all have a ECU or computer, as I know it.
For the EFIs, it turns on the fuel pump when you turn the key to run and shuts it off if you do not start engine in say 3 seconds or if the engine stalls.
All pressurised systems are very dangerous in an accident situation if the fuel pump keeps pressure as they can blast gas everywhere including on the exhaust. You can incinerate yourself. A toggle switch in a machine that has the fuel pump permently on does not solve this safety issue. Basically it just supports the use of the machine despite an already serious part failure. The ECU needs to control the fuel pump for safety.

I would advise, do not use that switch idea. Big risk. Do you have insurance like $1M liability? It would be void I bet if you make this mod.

OK, how to solve the issue.

My 2004 700 EFI has a solid-state "Load Shed Relay" that is activated by the ECU when the key is turned on. This relay sends juice to the pump under ECU control, including the safety shutoff I mentioned.

Mine recently shorted ( the relay ) and killed the battery. It heated up enough it melted down by the time I found it. The relay needs to be replaced. Main symptom was pump ran all of the time. One clear symtom is that , with the battery removed and the key off, the resistance between the two battery terminals drops from a normal 30,000 Ohms with no (failed) relay installed down to 2 ohms with the failed relay reinstalled and its metal case well grounded to the frame. That ia a draw of 6 amps or 72 watts!! A big short to ground. Use your nose: the burnt plastic/resin will stink!

My relay looks like a black rectangular box, cigarette pack shaped, and has wires with connectors on it. It has a back metal plate as a heat sink and for strength and mounting. It happens to be located under the front "hood" on the frame just below the handlebar headlamp. Standing in front of ATV looking back it is just below that lamp. It is screwed to the frame for ground and for heat sink. You can see this part as part number 30 on powersportplus.com, that have best prices.
Polaris ATV Parts 2004 A04CH68AU-CU SPORTSMAN 700 ELECTRICAL-TAILLIGHT - A04CH68AP-AQ-AU-CU Diagram


If your 2007 EFI has a similar part, or even a nice cheap old fashioned black "cube" relay ( mechanical) then I suggest that you find it as it may be the culprit. ECUs are $500. Relays less than $80. Relays are needed for high current like the pump, the radiator fan and the lights.

Good luck and please play this one safe. Fuel injection is no joke if tinkered with.

BearFish

 

@BearFish.
You are correct in that it is risky to use a switch to turn the pump on and off manually. However, Rooftop777 was only going to wire a switch to the pump wire so he could turn it off and on as temporary fix, not as a permanent solution. The 500 EFI is not the same as our 700 twins. It has a Power Distribution Module (PDM) containing two Solid State Circuit Breakers (SSCB). These SSCBs perform the same function as the relays and fuses would on your machine. They are just housed in one box that is supposedly unserviceable. Rooftop777 was able to open his, dry it out and make it work again.

Now that the real problem is fixed, we've moved on to talking about a switch on the positive lead only as a security measure. Apparently he goes to the store and to restaurants on his ATV. When he parks, he can disable the fuel pump circuit with a flip of the switch, which most would-be thieves wouldn't look for. In this application, with the switch turned on the safety circuitry in the PDM is still in control of the fuel pump.

Cheers,
Stew

 

@ BearFish
I just remembered. I believe there is/was a recall on the ECUs for your machine for the very situation you had with your melted relay. Some people even had fires that burned down garages and such.

Something you might check into if you haven't already.

Stew

 

Glad to hear the 500 is fixed

Glad to hear a good safe fix was implemented.
The switch idea is a good one for security purposes as you guys have said.

I will look into that ECU recall on my 2004 700 EFI. Thanks for the tip.

BearFish

 

Kids were over, quad perfect every time !
I did research on Recalls to register my vehicle from US to Canada....went to Polaris dealer, gave my VIN# then they printed off that there were no recalls for mine, so I'm clear and good-to-go.

Thanks again guys !!!!!!!!
From fixing up this salvage atv from top to bottom (and showing son how to), we learned lots and have already helped others here for 2 days, so happy that to give back in return.