I have a 2005 Sportsman 400 that is not charging. The battery light comes on and the owners manual says that it isn't charging and to rev it at higher rpms or charge the battery. Well, it won't charge at higher rpms any longer and charging it on a charger is only a temp resolution. It, for a while, would charge at 4600 rpm and higher. It no longer will charge at any higher rpm. The light comes back on once the battery falls off some.

I'm guessing the magneto is fried. It jump starts and runs until the battery runs down. Anybody have any thoughts as to what to look at?

Thanks for any help.

DWR

 

More than likely the ecm module has failed.It controls charging among other things. Even if you had the Chinese ecm replaced under the recall,the replacements can fail also.I've replaced multiple ecms on the same machines. If you still have the black finned Chinese module,you can have it replaced at no charge.Call your dealer with your vin # to make arrangements to have it replaced. If it's already been replaced,then plenty are on ebay. Surepower ECM 2004 2005 2006 Polaris Sportsman Scrambler 400 500 2203348 | eBay

 

how do I test it? it has been replaced under recall once already.

 

You already have checked it when you said the battery light came on and it's not charging back to the battery. Controlling charging is just one of the functions of the ecm.. Like I mentioned I replaced multiple ecms on the same machines. Sounds like time to get another one,only this time Polaris wont pay for it.

 

Ok thanks OPT. I took the front storage compartment off and located it, the big silver part on the front, eh? Well, I broke the gray clip that holds the plug in. I don't suppose the new one comes with new clip? Thanks for your help. You've given me advice more than once.

DWR

 

Should come in a box complete with harness and electrical grease.2004 2006 Polaris Sportsman 450 500 Scrambler Surepower ECM PDM 2203348 | eBay