I have a 1999 sportsman 500, my problems started on a big ride all the sudden i lost my gages lights and awd, and four wheeler would not start, i pull started it and lights worked for on sec then they died again, well i replaced the battery and now it starts great, but i still have no lights gages or awd, pls help, checked all fuses, guessing it's voltage regulator or speedo prob these modles somtimes have but not sure, any info would be great, ty

 

gee sounds like stator. or even a main ground wire disconnect. bad connection.

 

Check the bulbs, the battery works as a buffer, if the battery goes bad and you turn the lights on it will blow the bulbs, too much current.

 

I have seen several of that approx year that have the problems you stated and I found(several times) that some wiring under the front hood gets cut in half. It's usually a yellow wire and a brown wire. They can be kinda hard to find because it's in conduit. there is a main harness in there that splits off toward the headlight pod. There are several wire ties in there. Cut them loose and check for broken wiring.

 

Thanks for the advice guys, my battery was bad and i changed it, then i check the bulbs, and sure enough they were all blown, gonna replace them tonight, but i still wonder why my AWD switch is not working, and my winch, any advice would be great thatnks again.

 

What sould be the max voltage output of my voltage regulator, right now mine is at 15.63 is the to high, thats with lights on and fan, any input would be great thanks.

 

Sounds a little to high to me. I do not think it is supposed to go over 14.6. As far as the winch goes, there should be a solenoid somewhere that turns power on and off. Check that to see if it is working properly.

 

Ty for the info, the winch just started working again, i think the selinod is going bad, but i still can not figure out the four wheel drive, there is power to both sides of the switch, but dosn't seem to want to ingage, so lost lol, thanks for any light on the subject.

 

It could be possible that the extra voltage blew out the actuators inside the hubs, ut I am just guessing.