Hello, new to the forum.. Just bought a used 2004 Polaris sportsman. Its had a lot of work but theres more needed =(
Its eating batteries... The battery light flashes when I ride it which makes me think bad voltage regulator. thing is, I cant find it to save my life.. ive stripped the machine to rails and engine. Book I have says its under the rear fender.. Ive looked, not there.. Any help??


thanks.

Chris

 

Would help to know which Sportsman you have! 500,700? If it's a certain model 500 the regulator is close to the radiator. Item # 28 Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
Three other 2004 500 models were included in the ecm recall and it either has a black finned or silver finned module under the front panel down from the cdi and controled charging along with fan operation. If you have a black finned Chinese module,it needs to be replaced now! It's a free recall. #29 Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
Huge ATV Recall by Polaris - Sportsman and Scrambler

 

Sorry, its a 2004 Polaris sportsman 400. it is eating new batteries. I ordered a voltage regulator off amazon and believe they sent the wrong part. As I have stripped the machine down I came to a part listed as 1 of 2 ECM units. (I think) its a metallic "sure power 4011803". Thinking that's my culprit but its $150.

 

As I research this further.. It appears the machine was made in late 04, and uses the wiring diagram from the 05 model.?? Any help or insight there?

 

99% percent sure it's a bad ecm module. It controls charging plus the fan operation among other things. 2005 Sportsman 400 was covered under the recall,but not a 2004. I'd contact a dealer first to see if they can help,if not sounds like you may have to bite the bullet and purchase the updated one listed.Item #30. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

thank you old Polaris tech. Im gonna contact the dealer Monday, if I must eat the ecm I will.. Not happily but I need the machine to plow with. thank you

 

update:

Put the machine back together, new battery in, ran it around, setting up the plow. It wouldn't fail, I thought I got lucky, maybe bumped the ECM right or something. Sure enough, just as I get comfortable with it the battery light starts flashing at me. This time I noted that the fan kicked on when it started flashing.. Does that bump your 99% up at all?? Thank you again btw.. =)