Some folks already know this, but for those that don't let me save you a walk thru the woods.

On the 2004/2004.5 Sportsman 400 and 500HO the factory routed the plug wire down between the gas tank and the frame. It's pinched in there tight and will eventually ground to the frame leaving you stranded.

I talked to a dealer when my SP400 died the other day and he knew exactly what the problem was. He said it's a known issue and covered under warranty. I wish they would have told everyone before I got towed out of the woods by a Suzuki [img]i/expressions/face-icon-small-blush.gif[/img]

Anyway, if you didn't know about this, like me, here is a fix. Pull off the front rack and hood to get access to the coil. Loosen the 2 screws at the rear of the gas tank and pull it back a bit. Now you should be able to move the plug wire to the right (PVT side) about an inch or so where it will no longer be pinched. If you are still in warranty take it to a dealer and have them fix it. Either way, take care of it before if becomes a problem.