The four wheeler starts fine and when warmed up it dies. Head lights still work, but no electric start or pull start. About 1-2 hours later it will start up like nothing happened.

 

Sounds like an ecm is failing. 2004 model wasn't on the recall list but should have been.http://www.cpsc.gov/en/Recalls/2008/...o-Fire-Hazard/ The parts break down even shows that the black Chinese ecm changed over to the silver US made sure power module #2203348. 2004-2006 POLARIS Sportsman 450 500 Scrambler OEM Surepower ECM PDM 2203348 | eBay This module controlled too many functions,one section could work,another section could fail.Even the US made ones didn't have the the best reputation on holding up if it so happens the ecm has been updated already. Before I sprang for a 150 buck module,I'd do the ignition and trouble shooting tests from this cheap 5 buck manual.Could be something simple.2004 Polaris Scrambler 500 Service Manual PDF Download

 

I was also told it could of been the regulator, would that be false?

 

The regulator is built into the ecm module as well as the circuit breakers,controling the fan operation,hot light,controls power to the dash and a couple other things. The manual has some tests that can work around the ecm to see if there is some other problem and has a few ecm checks.