Well, the non-displaying gear is probably not causing the non-starting condition...has to be some other underlying condition. Battery connections tight? Are all the grounds clean and tight? Maybe check your fuses to make sure the are not corroded. Possibly a bad starter relay (shouldn't affect gear indicator though)?

I know the unit is relatively new, but have you had the battery load tested? A neglected battery won't last long at all. And just because it's showing a full charge doesn't necessarily mean it's holding voltage under load.

 

I would tend to agree with you that the non display shouldnt be causing the non-starting. However it's 100% consistent. If the gear indicator doesn't display, it doesn't start. If it displays it starts.

Battery connections are clean/tight, same with grounds. I haven't checked fuses yet.

I haven't had the battery load tested. That doesn't check out to me though. Meaning when the indicator works, it fires up with no hesitation. Also even when it doesn't start, I can turn the huge LED light bar on & the sound system and it powers everything fine.

The local dealer thinks its a bad gear selector switch. Is there a way to check ECU codes?

 

I'm looking at the service manual for my standard and its says that trouble codes aren't stored. They will display only if the engine light is on...for that ignition cycle. Once you turn the key off I think they're gone. If you get an engine light and you don't see a code then you need to toggle to the trouble codes with the mode button.

 

I don't know about the gear selector, but mine wouldn't start because of the pressure switch on top of the block that the brake lines go into on the frame. With the key on and pressing the brake, do your brake lights light up? If not, pull both seats and the back cover and look for the brake lines. Make sure that switch is fully seated and try again. Hope that helps.

nate

 

When the key is on and the RZR is not started, should the brake lights illuminate? Mine currently don't. Wondering if a brake sensor could be a potential issue?

Yup.

nate

 

Since you were working under the dash I would suggest you pull the display pod out and make sure the wire harness is is fully clipped on.

 

Dis-connect SSV and see if it's back to normal.:ride:

 

So she fired right up today. I've had several outcomes, where it won't start, I roll is 20ft by hand, try again and it fires right up. Coincidence? Not sure, but this situation has happened 3-4 times now.

I've read about people losing certain gears on the indicator and then not being able to switch from L to H. However haven't read of a situation where the entire gear range won't display and the RZR won't start. In the situation where the entire gear indicator won't work, should the RZR still start?

 

When the key is on and the RZR is not started, should the brake lights illuminate? Mine currently don't. Wondering if a brake sensor could be a potential issue?

 

if brake lights are not coming on it wont start... ck pressure switch on older 800 its behind drivers seat on frame rail youll see the brake lines going to the block on newer modles its on the master cyl

 

I found the brake pressure switch on the frame rail behind the drivers seat. I unplugged it, how do I jump it to test if its a faulty switch? Do I take a short piece of wire and jump the two terminals on the switch?

 

connect the two wires

 

I tried to jump the two wires in the plug with a short piece of wire and nothing. Still no tail/brake lights, no start.

I also completely unhooked he sound system...no change.

 

This morning I turned the key on and the tail lights came on. I put a test light on the brake sensor plug and it lit up. Still no brake lights however. I turned the key off, then on and now no tail lights or brake lights. Very hit and miss. Any ideas where to look?

 

Had the battery load tested at Napa. It wasn't fully charged however and was at 11.5v and had 181 CCA. Load test meter said it passed, but needed charged. I charged it up to 12.26v and put it back in the RZR and everything worked. Not sure if its related to the charge or its just randomly working as it has so many times in the past.

I tried to do the draw test with the key off as described in the book. I unhooked everything but the positive lead from the battery to the starter solenoid. I unhooked all the grounds and put my multimeter in series with the ground post on the battery and the ground terminal (that's no longer hooked to the battery). It read 11.56v. Book says it should be .01 or less. However it can't have a 11.56v draw or the battery would be wiped out right away and its held a charge all week (to alteast 11.5v).

Can a low voltage battery (11.5v) be causing all these issues? I bought another battery to wire in parallel with it, since I do have a few accessories (sound system with amp, LED lightbar, winch).

 

Yes, the low voltage could be causing your issues. If your battery can't hold voltage under load, it could cause some funky issues like you are describing. It's odd that your battery is down to 11.5v after only sitting for a week. Fully charged battery is around 12.6 to 12.8v. Should stay there for at least a few weeks before it starts to sag....unless of course you have something hooked up that draws when the buggy is off.

With that battery, what is your voltage at idle?

 

Wish I could tell you. Tried to start it, won't start. Battery is sitting at 12.2v, the gear indicator now works, however the check engine light is on. Tail/brake lights aren't working and it won't even crank. It cranked 30 minutes ago, not now...lol

 

I had all these issues as well as power steering light coming on and going out, the dealer had it for over a month( it was a brand new sportsman 550 xp le) and still couldn't figure it out, I was tired of dealing with it and had them buy me out of the sportsman and did a deal on my new rzr 800, it literally did what you are describing to a t, I will call the dealer Friday and see if they ever figured anything out with it and let you know if they tell me anything

 

Put a new battery in it, connected everything and it was golden. Fired up, lights worked, etc. Turned it off and tried again and now it starts without my foot on the brake, no headlines, tail lights or brake lights, no cigarette lighter, no AWD. Basically everything powered off the Chassis relay isn't working. All fuses are good. It has Error code: 0 520207 4 - "All wheel drive control circuit" "Driver circuit grounded".

I swapped every combination of the 4 relays. Whats weird is when I swap the relay from directly above the Chassis relay, the old problem comes up: No gear indicator, no lights, wont even try to start. And also the 520207 code goes away. When I swap them back (or any other relay), the gear indicator works, RZR starts, but still no lights or AWD and the error code is back.

So with the relay in place, the RZR will start, but no lights, accessories, or AWD. I checked the back of the fuse box with a test light. Only one wire has power, the other 3 don't for that relay (see the image). Also the Lights and the Drive 20amp fuses have no power.

Any ideas?

 

I know this is rzr-S specific but I'm having exact same issue on my std. rzr. No gear indicator, no rpm. was building pressure to the fuel pump when I turned the key to start position but after removing box to check the gear indicator fob I no longer am building pressure to the pump either. Have checked all my chassis grounds and I'm running a yellow top optima with full charge. Taking a screwdriver across the solenoid does turn it over but will not start obviously because it's efi. Gonna dig into it tonight again. Please post if you find something; I will do the same in return....I'm a journeyman electrician but not when it comes down to dc. Why can't things just be old school?

 

Got into mine again tonight. Gear indicator in perfect shape. For some reason I have an issue with my efi relay and the ecu ground input wire (dk green/yellow) always has 12vdc on it whether key is on or off. This wire goes directly back to the ecu as far as I can tell. now turned my key on and ran a jumper from the positive end of battery to the switched 12vdc off the efi relay (red/dk blu) and gear indicator works, fuel pump builds pressure, etc. Turn to start and nothing. checked starter solenoid coil, brake pressure switch, ignition key switch checks good. back to troubleshooting tonight. gonna check the condition of my wiring in general. Thinking I still must have a bad ground somewhere or two wires touchin that shouldn't be for the ecu input wire to always have 12vdc on it or my ecu is smoked.

 

I'm at my wits end with thing. It now has two brand new batteries in it, wired in parallel. Installed a volt gauge to verify battery level at all times. Battery is good, that's ruled out.

The issue is so intermittent thats its extremely difficult to chase. It basically boils down to 3 scenarios:

1) Everything works: Lights, all accessories, foot has to be on the brake, starts right up

2) 0 520207 4 - "All wheel drive control circuit" "Driver circuit grounded" - Entire Chassis relay is dead. No lights (headlights, brake lights), no AWD, no accessories. Still starts with NO foot on the brake.

3) No error code, no gear indicator on gauge. RZR won't even engage the starter, no accessories, no lights.

I can literally get all 3 scenarios within 2 minutes of each other, simply by turning the key on/off 3 different times. I can swap the 4 different relays between each other in the fuse block and get the above 3 different results. By changing absolutely nothing else, but moving relays around. Keep in mind these are identical relays.

Pulled the skid plate, inspected all wires, no signs of anything broke, nicked or pinched.

Not sure what else to do here. There is absolutely no rhyme or reason to these errors, completely random. All I know is I wouldnt trust taking this thing past the end of the driveways...that's even it even started.

 

Once you do get it started, drive it out of the garage and onto your trailer. Then turn the RZR off...start the car, and drive to the Polaris dealer.

At this point its worth paying to have the experts fix it.

 

I got mine running the other day. Went back. I ran a jumper from red/dk blu off the efi relay to +12vdc on the battery. turned the key and started right up. So now I have officially jumped out the efi relay temporarily (will need to do something permanent soon) and rzr starts and runs great. took for 10 mile round trip that day with no further issues. Definitely thinking there is a short in the ecu for that dkgreen with yellow stripe wire. *ecu ground input*. Oh well; it runs and I saved a trip and a $50 deductible from having the dealer fix it for me and take 2 months to get it done.

 

I got mine running the other day. Went back. I ran a jumper from red/dk blu off the efi relay to +12vdc on the battery. turned the key and started right up. So now I have officially jumped out the efi relay temporarily (will need to do something permanent soon) and rzr starts and runs great. took for 10 mile round trip that day with no further issues. Definitely thinking there is a short in the ecu for that dkgreen with yellow stripe wire. ecu ground input. Oh well; it runs and I saved a trip and a $50 deductible from having the dealer fix it for me and take 2 months to get it done.

I'm currently having the exact same issues with my 2020 1000s, where did you run your jumper wire from and to to be able to figure out your problem??

 

Thank you. I just ran a jumper wire to key on 12 volt. Rzr starts every time no problem. You saved me hours of work. I work at an ATV shop. Your info was very helpful.

 

I'm currently having the exact same issues with my 2020 1000s, where did you run your jumper wire from and to to be able to figure out your problem??