Locked04 Sportsman 500 - Electrical issues

Post
craka
Mud Master
2011/09/22 22:57:16
I just traded for this machine and new to it. Has anyone had any problems with the electrical shutting the machine down while riding? It's almost like it's shorting out. I don't think the battery is very strong on it. It was fine until it started raining. It would run fine then the lights would shut out and it would sputter a little and then cut back on. It cut off a few times. Sounds like I got another t u r d to work on (rhino isn't enough!).  Anyone got any good starting points?
Po_700_Po
Mud Master
Re:04 Sportsman 500 - Electrical issues 2011/09/23 19:52:32
Start with the red kill switch. Had one go bad on my '02 500.
craka
Mud Master
Re:04 Sportsman 500 - Electrical issues 2011/09/24 10:43:55
ok... tested all the hot and grounds going to the ecm. they have power. i had tried earlier in the day to mess with the red kill switch and got no results. it fired back up after plugging the ecm in and moving the kill switch. now, it randomly cuts off while riding. to get it to run, i have to push the kill switch to the left and then center it and everything comes back on. i'm hoping it is the kill switch.
 
other issues include the battery light flashing. the bendix on the starter doesn't engage. the head lights dim when i hit the gas. i am going to start with the kill switch. any way to test the ecm?
BridelessRacing
Respected Member
Re:04 Sportsman 500 - Electrical issues 2011/09/24 11:34:37
IMO Circuit breaker bag has water in it. Cut it out of circuit and install a fuse holder.
craka
Mud Master
Re:04 Sportsman 500 - Electrical issues 2011/09/24 16:20:06
Where can I find that at? I haven't seen a circuit on it yet.
craka
Mud Master
Re:04 Sportsman 500 - Electrical issues 2011/09/24 16:22:17
I also rode it for about 5 miles when I traded for it... no problems. Then it started raining and that's when all this started.
BridelessRacing
Respected Member
Re:04 Sportsman 500 - Electrical issues 2011/09/24 18:06:47
Right in front of battery. Black bag with a red wire running through it.
craka
Mud Master
Re:04 Sportsman 500 - Electrical issues 2011/09/25 11:26:24
All I see is a solenoid.
BridelessRacing
Respected Member
Re:04 Sportsman 500 - Electrical issues 2011/09/25 18:18:59
Inside this bag is a circuit breaker [and usually water that shouldnt be there]

cut the bag out and replace with a fuse holder soldered and heat shrinked in place. like so

craka
Mud Master
Re:04 Sportsman 500 - Electrical issues 2011/09/25 20:02:38
I followed all the wires and I'm not seeing anything like that. The speedometer is moving up and down while the atv isn't moving. It cuts out (engine only), still has electrical when in reverse sometimes. The only way to get it running again is to turn the key off and back on. I'm wondering if its the ecm.
craka
Mud Master
Re:04 Sportsman 500 - Electrical issues 2011/09/25 20:07:47
anyone have a pdf shop manual they would be willing to share??
BridelessRacing
Respected Member
Re:04 Sportsman 500 - Electrical issues 2011/09/25 20:34:42
the 4 inch long ground wire on the top motor mount is it still conected?
Post me a pick of your lower headlites and a pic of the radiator cap
gotmuddy
Respected Member
Re:04 Sportsman 500 - Electrical issues 2011/09/25 20:45:57
yours may have a box that controls all of it under the hood.
craka
Mud Master
Re:04 Sportsman 500 - Electrical issues 2011/09/25 20:51:38

 

 

 
thanks... i appreciate your help!
gotmuddy
Respected Member
Re:04 Sportsman 500 - Electrical issues 2011/09/25 20:57:24
that box is your problem.
craka
Mud Master
Re:04 Sportsman 500 - Electrical issues 2011/09/25 21:08:03
I'm thinking the same. I wish there was a way to test it before shelling out the cash on a new one.
BridelessRacing
Respected Member
Re:04 Sportsman 500 - Electrical issues 2011/09/25 22:17:05
got muddy figured what i was up to your bike is actually a 2004.5
BridelessRacing
Respected Member
Re:04 Sportsman 500 - Electrical issues 2011/09/25 22:18:21
now give me the no off the end of the surepower modjule
craka
Mud Master
Re:04 Sportsman 500 - Electrical issues 2011/09/26 06:31:21
4010937
BridelessRacing
Respected Member
Re:04 Sportsman 500 - Electrical issues 2011/09/26 13:52:26
Call your local dealer that box is a factory recall I'm almost certain
craka
Mud Master
Re:04 Sportsman 500 - Electrical issues 2011/09/26 14:58:19
no luck man! no recalls on mine... just a service bulletin about a possible pinched coil wire that expired last year. the surepower part is now superseded by part 2203348 in the fiche... would be nice if it was in the recall.
craka
Mud Master
Re:04 Sportsman 500 - Electrical issues 2011/09/27 09:52:33
Ok, now I am not seeing a battery light flashing. The atv will drive around with out cutting off in forward. It will shut down in reverse at a certain RPM if I do not use the override button (engine dies, not electrical). I rode it around for 5 miles and the speedometer didn't lose power once. The speedometer still moves when it's parked...
craka
Mud Master
Re:04 Sportsman 500 - Electrical issues 2011/09/27 10:04:13
Does the ECM have anything to do with charging the battery or is there a stator?