Thanks admin
I did look at this thread but i switched the relays around and the "bad" one would work in the other spots and "good" ones I switched from other spots wouldn't work in the chassis relay spot. Also in the thread someone says the chassis relay works the lights but the lights work when it is in or out but wont start with any relay in I guess i could buy a new one but swapping them does nothing thanks, wha happens if you run without the relay?:question:

Steve

 

old post about the 2011 XP......

EFI relay out:
NO brake engaged: - cluster illuminates - fuel pump pumps - no starter
with brake engaged: - cluster illuminates - NO fuel pump - no starter

applying the brake disconnects the fuel pump
Chassis relay out:
NO brake engaged: - cluster illuminates - engine starts (not a misprint)
with brake engaged: - cluster illuminates - engine starts

 

Thanks itsruf
From your post Chassis relay out:
NO brake engaged: - cluster illuminates - engine starts (not a misprint)
with brake engaged: - cluster illuminates - engine starts
Yes this is what happens but when I swap relays from another port no chane if any relay is in there no start no relay it will start brake or no brake engine light comes on
any relay...no start I did search this post before posting but there is no answer as to what the problem is or how to resolve it
ANY idea how to fix it or what the problem is
Please?

 

Is there any chance you have some moisture in the chasis relay wiring/connection...wd40!

 

Negatory on the moisture. I am in so cal desert riding no moisture and I am sorry to say I have not washed the beast in months!

 

Looking in manual you should have 30A fuse for C and D for the seperate 3 slot block under the seat. by your description of changing seats is there anything that looks different? pinched wires etc. Is this fuse in the center blown? If you disconnect battery and with chassis relay removed, measure ohms from pin D to ground does it show open(infinite) or short. I could see how if the fuse is blown and showing a short it wouldn'd start if the relay was in.

Moving from the chassis relat out, it controls lights(20A), drive(awd)(10A), and acc (20A) points. pulling these fuse in some order should help to identify where the issue is. I would pull the 10A drive first with relay in and see if it starts. if id does you at least have a direction to go.

 

I will give it a go! I did not see any pinched wires anywhere but you would think it would blow the fuse if there was. This has been most helpful though because if that relay controls those items I do have a place to start. The lights do work when the key is on relay but no start I will let you know what I find The RZr is in my storage so I will have to wait until Thursday
Do you thing there will be any damage if I run it without the relay in?
The check engine light comes on ?
Thanks
Steve

 

i would ck the wireing over again it sounds like a wire is shorted togheir or shorted to ground you said when you jumped it with a battery it shorted??? discribe this better

 

I originally thought the battery was dead so I tried to jump it and when attaching the battery I had the jumpers attached to the RZR and touchd the other ends of the cables together when trying to attach the cables to the other battaer just for 1/2 of a second. Quick small sparks...oops

 

O.k guys here is the answer!
Underneath the seats on an RZR S ( closer to the driver) is a switch it is circular, metalic, and sits on the Square junction box where the brake line splits from 1 to 2 to go the the rear axles. That is the brake safety switch. It had come SLIGHTLY off. On first examination it appeared to be on but I pushed it harder and BOOM, she fired
The dead giveaway was, with the chassis relay in, key on, no brake lights! The chassis relay must control this switch so with it out, the RZR would start with brake pedal depressed or not.
Thanks for the reply's guys You have always been nmost helpful and Hopefully this might help someone else with this if it should happen
Thanks AGAIN!!!
ducman24

 

Hooray!!! You got it fixed! Now you can go back to sleeping nights again.......LOL. Electrical gremlins, especially really odd ones, can drive a man to drink. Glad to hear that you whipped it.

Cheers

 

great post! love the way we work together to solve these problems.... Had the same problem last night night after changing out my 20 amp circuit breaker... pulled relay fired up, check engine light came on so i put back in the relay and light went off and ran fine... looks like I need a new chasis relay... any other ppl experience this?

 

Here is my story from this weekend:

Background: Rode Turkey Bay in the RZR yesterday, Saturday. They had a 1.5" rain in ten minutes Friday, place was washed out worse than ever seen before, and a lot of rocks washed to the top or the dirt was all washed away leaving the place very rocky. Had a friend of my sons with me in the RZR. He wanted to ride in it. So there we where, back in the woods, came up on two people on motorbikes and one still on the hill, pushing bike back down, she had rolled a rock under the front tire and crashed, broke the clutch lever off of the handle bars, we pulled out a few zip ties and they rode with us another hour.... after...."we got my RZR to start". Hit the key, all of the lights come on, fuel pump runs, starter does not engage....I reassuring told my sons friend, Brandon, "that I don't have a clue".

Now, we are back in the woods. I say out loud, I swear this acts like the brake pedal is not depressed, but it was. Brandon, very motivated, says lets rock it, so we do, in gear, hit the starter, varooom! We all decide to head back towards the truck. Motorbikes too. Get there, without incident, shut RZR off, starts, Varooom!...couple more times decide to ride, invite motorbike riders to join in, They do, we rode another hour on the easiest trails there which were washed out worse than ever seen before....still a little leery on my RZR, want to be able to get to it with the truck. Get home wash it, all good, leave in yard to dry and wash some more today. Son goes to put it up tonight...nothing, same deal. Everything powers up, fuel pump runs starter does not engage. So my son looks distressed but I told him the best news is it acted up here in the yard.

Pull the manual out and start reading, did a quick look for the brake position sensor, could not find it under the dash or on the master cylinder, back to the book. Page 10.38 of manual, STARTING SYSTEM FLOW CHART:

Check battery voltage...I did with a meter..checks good.

Disconnect the two wire deal coming out of the solenoid, check voltage, Orange wire is negative and positive is Green/white wire, should have 12 volts, nothing.

Book sends me to the EFI 20 amp fuse, check voltage, normal, book says my key switch is bad, Book tells me to check voltage there...I do not know how to do that, and fat people do not fit up under the dash of these things...so I decide to skip that and go to solenoid. Start checking wires...blah blah blah....look down just past the solenoid, and low and behold, there is a electronic sensor with brake lines running out of it. I have been looking for that, so I move it, kinda loose, hit the starter....varoom! Pull wire off and clean with some wd-40...varoom.

Write that down in your book to check when your RZR wont start in the woods. And, this is not on page 10.38 of the manual.

Special thanks to my wonderful wife who held the flashlight while the mosquitoes had a fiesta.

 

Hopefully this helps. I got a 2012 rzr s 800. I've come across a few issues along the way. The first issue was when you would go to turn the key on I had no power at all but could hear the relays clicking so I checked all the fuses all the grounds and everything seemed to be OK. It stumped me at first but I ran a power wire direct to my own switch to the ignition and then everything worked. The battery was new but was only at about 80 percent when I was diagnosing this issue. I ran the rzr like this for.months and then one day I went down to start it and the battery was dead. No big deal I let the battery charge over night and everything came back to life. Without having to use the direct power wire. The battery caused my machine to do more goofy things then u would imagine. Problem number to I was riding and I had a issue with the fan not coming on and no lights so I went home checked all the relays and fuses everything was good I then checked the circuit breaker under the seat and it looked pretty ugly so I replaced it. Advance auto parts has them for like 4 bucks. Put that in there and everything works great