Locked04 Sportsman 500 - Electrical issues

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?

Start with the red kill switch. Had one go bad on my '02 500.

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?

IMO Circuit breaker bag has water in it. Cut it out of circuit and install a fuse holder.

Where can I find that at? I haven't seen a circuit on it yet.

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.

Right in front of battery. Black bag with a red wire running through it.

All I see is a solenoid.

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

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.

anyone have a pdf shop manual they would be willing to share??

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

yours may have a box that controls all of it under the hood.

 

 

 
thanks... i appreciate your help!

that box is your problem.

I'm thinking the same. I wish there was a way to test it before shelling out the cash on a new one.

got muddy figured what i was up to your bike is actually a 2004.5

now give me the no off the end of the surepower modjule

4010937

Call your local dealer that box is a factory recall I'm almost certain

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.

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...

Does the ECM have anything to do with charging the battery or is there a stator?