Ok Thanks for the forum, my first time. So, my problem began when I changed the battery on my 2005 polaris sportsman 500 HO. I accidently connected it backwards and the fan motor ran. (for about 30 s) When I realized what I had done I correctly re-established the correct connection. Since then my battery light flashes after starting and the battery tests up to 17V and is boiling. I changed to a new battery no help. I changed the voltage regulator and no help (still the same). New stator and after about 30s light flashes again. I'm pretty much at a loss, I know there is a CDI throttle module but don't know know if that has anything to do with the battery.
We don't have a polaris mechanic where I live ,closest about 50 miles away. I'm thinkng about changing the battery again or is it poss the new voltage regulator is bad. Any help would be appreciated!
Thanks

 

You changed the Stator as a fix try?
Maybe the ECM brain box. The 2005 had a recall on those as it is. ATV: Polaris Ind. expands recall of ATVs That thing can cause all kinds of electrical problems.

Leave the expensive stuff like Stator and CDI for last although the ECM is not cheap, but if the recall was not done Polaris will change it for free since its a government safety recall with no time limit.

 

Thank you for the info. yes i don't claim to be a genius its just that I had problems with my polaris 400 and it ended up being the stator and other threads I have seen on this forum suggested it might be the stator, so I tried it. Anyway the ECM makes sense I'll try it and let you know.
Thanks again for the help!!

 

You said you changed the voltage regulator and considering changing the ecm?? You can't have both on the same machine.The ecm takes the place of the voltage regulator on earlier machines and controls charging,fan operation and has several internal circuit breakers. Plus "cdi throttle module" ?? Here's a cheap 5 buck manual that can help on electrical and other repairs.
2005 Polaris Sportsman 500 Service Manual PDF Download

 

Well TLC. Thanks for the info. I finally got around to changing the ECM and the machine is back to normal again. Another learning experience! Thanks again!! PS it looked like it was changed previously probably from the original owner and recall.

 

This is still an ongoing problem even from Polaris changing from the Chinese modules to the American made Sure Power ecms. We've replaced modules several times at the shop on multiple machines. Hope this one holds up for you.