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Discussion Starter #1
Owners manual covers 500 & 800 EFI
Says fuse block for 800 is on top of the access door.
Does not say the 500 even has a fuse, let alone where they may be.
There is nothing on/under or near the access door. Cannot find a fuse block anywhere.

My two questions are: Where is the fuse block located on a 500 &
where is the fuel filter?
ATV has been sitting (w/o) gas for about 5 years. Tank was drained then.
New gas & battery. Cranks over fine and will fire on staring fluid.
Has spark but not getting gas.
Any help is appreciated,
Tom/Idaho
 

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Owners manual covers 500 & 800 EFI
Says fuse block for 800 is on top of the access door.
Does not say the 500 even has a fuse, let alone where they may be.
There is nothing on/under or near the access door. Cannot find a fuse block anywhere.

My two questions are: Where is the fuse block located on a 500 &
where is the fuel filter?
ATV has been sitting (w/o) gas for about 5 years. Tank was drained then.
New gas & battery. Cranks over fine and will fire on staring fluid.
Has spark but not getting gas.
Any help is appreciated,
Tom/Idaho
What's the VIN?
It wouldn't be a 2007 would it?
10th digit is the model year.
 

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Discussion Starter #4
My mistake, yes it's a 2007.
My500/800 manual says the 800 has a fuse block below the access door. Nothing on the 500. In fact there is not a fuse block anywhere.
I found the fuel filter, but can't figure out how to change it.Any help, Thanks, Tom/Idaho
 

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My mistake, yes it's a 2007.
My500/800 manual says the 800 has a fuse block below the access door. Nothing on the 500. In fact there is not a fuse block anywhere.
I found the fuel filter, but can't figure out how to change it.Any help, Thanks, Tom/Idaho
That's what I suspected. The 2007 electrical harness configuration is very different than the 2008. No fuse block or relays under the access door.
The fuel filter has quick couplings on each end and simply snaps in the plastic holder it sits in. You squeeze the end tabs of the horseshoe-shaped locks on the couplings and push up just till they disengage. They only raise up about 1/2". Then you push the coupling in toward the filter and then back out the other way to pull it off the filter. Pour a some fuel in the new filter to wet it and install in the reverse order.
Here's a pic.
 

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Owners manual covers 500 & 800 EFI
Says fuse block for 800 is on top of the access door.
Does not say the 500 even has a fuse, let alone where they may be.
There is nothing on/under or near the access door. Cannot find a fuse block anywhere.

My two questions are: Where is the fuse block located on a 500 &
where is the fuel filter?
ATV has been sitting (w/o) gas for about 5 years. Tank was drained then.
New gas & battery. Cranks over fine and will fire on staring fluid.
Has spark but not getting gas.
Any help is appreciated,
Tom/Idaho
I just reread your original post Tom.
Can you hear the fuel pump prime up when you turn the key on?
If the pump runs, cycle the key on/off multiple times (6-7) and then see if it tries to hit when cranking.
If its not pumping check if you're getting power to the pump at the connector on the top front of the tank.
Let us know what you find.
 

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Discussion Starter #7
Thank you for you assistance. I have that same schematic, and thank you for the info on how to unhook it, but I haven't figured out how to reach the filter.
Also does the ECM take the place of fuses and/or relays. If it does that could be what's not letting it start. This ECM was dealer replaced just before it was put in storage and the machine has less than 1000 miles on it with only a hundred or so on the new ECM.
When I turn the key on everything lights up and the starter works great.
Turn off the key and I can hear clicking for a couple seconds. Sounds like an electric fuel pump sounds. If that is the electric fuel pump,shouldn't it make the clicking sound when the key was turned on and not after?
Again, I thank you for your continued help,
Tom/Idaho
 

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Discussion Starter #8
I tried the key cycle as described in the owners manual. It said to do it 3 times with 5 seconds on and then off.
Did not change.
Why would it try to prime (if that's what it's doing) after I turn off the key?
Again thanks,
Tom/Idaho
 

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When you turn the key on it should whir/buzz/spin while it pumps for about 5 seconds to build up pressure. You can hear it run loudly. It doesn't just click.
 

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Discussion Starter #10
Okay, it does not make any noise when the key is turned on. Makes only the clicking sound when I turn the key off.
What do I need to do to make it do what it should?
Thanks, Tom/Idaho
 

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Discussion Starter #13
I have the plastic and box off the front. This fuel tank is different as it is a 2007(or so the registration says).
The fisch(that I copied and you sent) says that image is for a 2006 which would explain why there is nothing on the top rear of this tank to connect to or test.
When I put information into the fisch locator I put in 2007 and it shows a fisch for 2006.
Any idea what to do now?
Thanks, Tom/Idaho
 

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I have the plastic and box off the front. This fuel tank is different as it is a 2007(or so the registration says).
The fisch(that I copied and you sent) says that image is for a 2006 which would explain why there is nothing on the top rear of this tank to connect to or test.
When I put information into the fisch locator I put in 2007 and it shows a fisch for 2006.
Any idea what to do now?
Thanks, Tom/Idaho
Tom, the design and drawings for these machines are done a year or two BEFORE production. They all are. Those for a 2007 will have been done in 2006 or earlier and so on. You're looking at the tank wrong. The pump is in the FRONT right side of the tank just like the drawing shows. You'll have to follow the wires and pull the tank back some from the bulkhead to find the connector. Unplug the connector, turn the key on and use a multimeter to see if you have voltage coming through the harness to the pump. If you have voltage but the pump isn't running when you turn it on you must have a bad pump. If you have no voltage going to the pump then you're losing it upstream somewhere and we'll have to track it down.
 

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Discussion Starter #16
You're looking at the tank wrong

You are right, I was. I see that now. I think I may just up and quit for the day. Damm!

At the connector are three wires. 1) Red/Green 2)purple/white 3)Brown
Key on; red/green=1.17 DC volts
purple/white=5.03 DC volts
brown=ground
As I don't see any fuses I'm guessing one of the little boxes control that missing voltage.
Or, am I still missing something?
Hey, I really do appreciate you leading me by the hand.
Tom/Idaho
 

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Discussion Starter #18
Shouldn't I have battery voltage at the connector?
Can I put 12 volts in the purple/white wire to the pump end of the connector
to test the pump?
 

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If you don't find any problems with the battery or the harness back toward the PDM it may be a problem in the PDM itself as that controls everything rather than relays like on the 2008.

Edit: I edited this post to reflect that its the PDM that does the power distribution on the 2007 rather than separate relays and fuses.
 
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