Battery drain/over charging.
 

I have an 04 or 05 sportsman 500ho anniversary edition that eats batteries. Also last time i tried to use it the dash started flashing and stalled when I gave it gas. In the diagnostic mode it showed a charge rate of 19.4 volts . Any ideas?

Ecm module. If you haven't had it replaced(some still out there with the black Chinese ecms)it was under recall at no charge.Polaris Industries Expands Recall of ATVs Due to Fire Hazard | CPSC.gov If you have the replacement silver Sure Power ecm module,then they have been known to be just as faulty. This module controls charging ,fan operation among other things.http://www.ebay.com/itm/like/171576768506?lpid=82&chn=ps&ul_noapp=true Early 2004 models had the voltage regulator close to the radiator. It could do the same thing on over charging/undercharging as the ecm could.http://www.ebay.com/itm/NEW-VOLTAGE-...tXIMMK&vxp=mtr

I'll have to check and see which one I have.
 

[Thank you.QUOTE=old polaris tech;3326765]Ecm module. If you haven't had it replaced(some still out there with the black Chinese ecms)it was under recall at no charge.Polaris Industries Expands Recall of ATVs Due to Fire Hazard | CPSC.gov If you have the replacement silver Sure Power ecm module,then they have been known to be just as faulty. This module controls charging ,fan operation among other things.http://www.ebay.com/itm/like/171576768506?lpid=82&chn=ps&ul_noapp=true Early 2004 models had the voltage regulator close to the radiator. It could do the same thing on over charging/undercharging as the ecm could.New Voltage Regulator Rectifier for 400 500 600 700 Polaris Sportsman 2003 2004 | eBay[/QUOTE]

Hope you have the early model with the regulator,a lot cheaper than the ecm module.. Keep us updated.

Have the sure fire.
 

I checked and found have the surefire ecm. The machine manufacture date is March of 2004. I had it at the shop for the fan coming on sporadically even when sitting for a few days. About 9 years ago. I remember them replacing the ecm under a recall. I checked all connections and it looks like I'm buying a new ecm.. is there a way to test the ecm that's in it ? Like I said before, it eats batteries and it says it's over charging.. am I best off just buying a new one??

Just get a new ecm module. Had a bunch of problems like this on the replacement US made ecms also. Fans would run constantly running batteries down,charging either too low or way too high. The module controls too many things imo. Fan operation,charging,battery protection circuit(that's a joke)plus all the circuit breakers are in this module. Here's an example of one that melted internally.

Thanks for the help..
 

Thanks for the help. Much appreciated. I'll be buying a new one soon. I'll get back to you sometime on the results..