Polaris 2012 Sportsman Forest 500 International, Service Manual

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4.62
500 EFI FUEL SYSTEM
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Engine Controller Reprogramming (Reflash)
Process Overview
The reprogramming feature is in the Special Tests menu
on the Digital Wrench™ screen. Start Digital Wrench™
and click on the Special Tests menu icon (red tool box). A
technician should be familiar with the process and with
computer operation in general before attempting to
reprogram an ECU.
The Digital Wrench™ Engine Controller Reprogramming
(or “Reflash”) feature allows reprogramming of the ECU
fuel and ignition map. To successfully reprogram the ECU,
an Authorization Key must be obtained by entering a
Request Code in the box provided on the Reflash
Authorization site. The Request Code is automatically
generated by Digital Wrench™ during the reprogramming
process. The Reflash Authorization site is located under
the “
Service and Warranty ” drop down menu on the
dealer website at: www.polarisdealers.com .
IMPORTANT: Failure to follow the reprogramming
instructions completely and correctly can result in an
engine that does not run! Replacement ECUs are
programmed as “no-start” and require a reflash for
them to work.
Reprogramming (Reflash) Tips:
• BATTERY VOLTAGE: The majority of problems
with reprogramming can be attributed to a low
battery. Be sure the battery voltage (no load) is at
least 13 volts and at least 12.5 volts with the key
‘ON’. Connect a battery charger if necessary to
bring voltage level above minimum. Fully charge
the battery before you attempt to reprogram.
• DEDICATED LAPTOP: Best results are obtained
using a laptop computer that is “dedicated to
Digital Wrench™”. A laptop that is used by a
variety of people and in several applications
around the dealership is more likely to cause a
reprogramming problem than one dedicated to
Digital Wrench™ diagnostics only.
• OBTAINING THE LATEST UPDATE:
Reprogramming updates are provided periodically
and contain the most recent calibrations (see
“Digital Wrench™ Updates”).
• CLOSE NON-ESSENTIAL PROGRAMS: Polaris
recommends that you DO NOT install non-
essential programs on a Service Department
laptop. Camera detection software, Virus
Scanners, Tool Bars, etc. may clog up memory if
running in the background and make it harder for
the diagnostic software to operate.
• KNOW THE PROCESS: If you are not familiar with
the entire reprogramming process, review the
HELP section of the diagnostic software before
you attempt reprogramming. Click on the
? on the
tool bar or press F11. The information in the on-
line help is the most current and complete
information available. This should be your first
step until you are familiar with the process.
• COMMUNICATION PROBLEMS: If you have had
problems communicating with a vehicle while
performing diagnostic functions, do not attempt
reprogramming until the cause has been identified
and fixed. Check all connections, and be sure
battery voltage is as specified.


Proceed to http://polaris.diagsys.com for
specific information and FAQs on how to
troubleshoot communication problems.
• DON’T DISTURB THE PC: While reprogramming
is in progress, don’t move the mouse and don’t
touch the keyboard. The process only takes a few
minutes, and is best left alone until complete.
Reprogramming (Reflash) Procedure:
If you are not familiar with the reprogramming process,
review the “Reprogramming (Reflash) Tips” before you
begin. Follow the on-screen instructions as you progress
through the steps. If you encounter a problem, always
check the On-Line help for current tips and information.
1. Verify the most current update has been downloaded
and loaded into Digital Wrench™. See “Digital
Wrench™ Version and Update ID” on page 4.59.
2. Connect the SmartLink Module cables to the PC and
vehicle. See “Digital Wrench™ - Diagnostic
Connector” on page 4.58.
3. Open the Digital Wrench™ program.