I'm new here guys. Did a few searches on my problem and kept getting directed to this site so I signed up. Here's my issue.

2003 Sportsman 500 - Very Used

Several years ago the unit blew the fusible link. Needed a quick fix while up north so I replaced the link with an inline replacable fuse. Fix worked for years. Recently it keeps blowing fuses...instantly.

It starts fine and will idle with no problem. As soon as I give it gas the fuse blows. Battery reads 12.4V with key on/engine off. 12.4V with key on/engine running all the way up to 3K RPM or so. I've cleaned the battery terminal and the engine ground. Battery is 2 or 3 years old.

I can't find a dead short anywhere. I've traced all the wires I can find as best as I can. No bad connections, no arc marks. Tracing isn't easy so I may have missed one.

Engine will pull start with fuse blown but digital display is erratic at best and headlight is faint or flickers.

Also, 4WD doesn't always disengage. Wants to pull to the right for a short time before releasing. I know this magnetic coil deal is electric. Could this be my dead short?

I'm at wits end here. I'm not great with electrical to start with but this is driving me crazy.

Any help is greatly appreciated. Thanks in advance.

Steve

 

Here is whats involed with the hubs, http://www.atvtime.com/phpBB2/viewto...003&pc_t=12521

Sounds like your rectifier ( Controls Voltage) is not working if I had to guess. Its by the top of rad.
Part 35, Part number 2203638 or 4010670 OEM motorcycle and ATV parts from Honda, Yamaha & Polaris – Cycle Parts Warehouse