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Old 12-15-2008, 01:42 AM
Weekend Warrior
Join Date: Dec 2008
Posts: 3
Default 2004 sportsman 500

I managed to hook up a new battery backwards and got a good puff of smoke from the front end. I assume it may be a circuit breaker or fusible link. I am not sure where they are located or what they look like. I would appreciate any help or suggestions. John
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Old 12-15-2008, 03:08 AM
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Polaris ATV Expert
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Default 2004 sportsman 500

20 amp close to the battery and 10 amp under front cover, both in plastic pouches,HOPE its just that and nothing else! After hooking battery back right,check with test light if have voltage on red wires on each side of pouches OR may be able to see visually for any burnt wires! PS Cant handle the *****! Blood pressure going up!!!!!
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Old 12-15-2008, 10:19 AM
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Join Date: Jan 2007
Location: Troup, Tx
Posts: 1,047
Default 2004 sportsman 500

circuit breakers fuseable link or fuses dont really care what direction electricity is flowing. more than likely you got a peice of electronics like the cdi box. a good way to tell is remove the cdi box from the motor and do the sniff test to see if it smells like burnt electronics.
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Old 12-15-2008, 11:48 AM
Pro Rider
Join Date: Apr 2005
Posts: 397
Default 2004 sportsman 500

I did the same thing a little over a year ago. My puff of smoke turned out to be the ECU, ECM. which ever you choose to call it.
$130.00 Pretty easy to change. just PO'd me for throwing away some hard earned cash.
It didn't seem to do any other damage but sniffing around will definately be a good way of finding out what you smoked.
Good luck.
@$%# happens
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Old 01-31-2009, 11:28 PM
Weekend Warrior
Join Date: Dec 2008
Posts: 3
Default 2004 sportsman 500

Got a new battery that had the poles reversed and hooked it up backwards. Got a puff of smoke from under the front, also a sizzle noise. Put in correct battery and had no power to switch. put a volt meter between battery and neg. cable and was reading 12.84 volts, same as battery. does this mean I have a dead short? When i disconnected the ecm it drops to 12.06 volts, when I unplugged the speedo it stayed at 12.84 until i unplugged the ecm then it dropped to zero. does this mean the ecm is bad or both ecm amd speedo? I can not find any burnt wiring or sign of damage anywhere, although ecm smells burnt. How can I tell what is really bad without just buying parts? By the way the 04 1/2 had the first ecm that had the circuit breakers built in with the regulator and temp control box that is called the SSCB on the wiring diagram or ecm or logic box in the manual. Thanks for any help anyone can give me. JT
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