I have an 02' polaris sportsman 700 twin. I am having a problem with the whole machine's electrical system flashing like a strobe light. It only happens once the machine warms up for a few minutes. I have replaced the voltage regulator, cylinoid (winch), starter cylinoid, light switch (on bars), and I am in the stages of insanity trying to figure out what next? Anyone help me?

 

need alittle more info.....are just the lights flashing or is the machine running like crap also?

 

machine runs great, just hear a "clicking" in the winch cylenoid when the lights are flashing. The entire electrical system flashes when it warms up, and you can feel the winch cylenoid heating up like it is shorting.....I just replaced it, still no fix.....otherwise, machine RUNS great

 

sure sounds like a ground problem.....the machines are really touchy with grounds, you have to have a perfect connection and tight....I would pull all ground connections and thoroughly clean and re-tighten. Pull the ground a power wires at the battery, the wires at the contactor (solenoid) for the winch and thoroughly clean and retighten. My contactor for my winch kept clicking and the winch would work sometimes and not others. At the battery I had the power cable on top of the regular power cable, it was tight, but still wasn't making a good contact, I reversed the two, made sure they were flat and tightened, no problems since.

If you have a DVM (Digital volt meter....i.e. multimeter), you should be getting less than 200m Ohms (milliohms) across than any connection., if you are getting more than that, you have a bad connection...

dave

 

I disconnected the entire winch from the battery, to see if it was from there, and it still flicked, minus the click in the cylenoid...obviously with no juice to it, but it still flickered throught the display and lights......how many grounds are there, and are they "hidden"?

 

The main ground wires are connected usually to the frame on the left side of the machine (when looking from the rear) right near the battery. There should be a few wires mounted to the frame there. Check them. You may have to use a DVM to find where the problem is. I doubt something is bad because it is flashing, its most likely in the ground system, its loosing its connection, etc.

 

This was in another part of Polaris problems, what do you think my chances are the same problem?

"I had sort of the same problem last week. My display went dead when I turned my low beam lights on, I turned them off and my display would come back on. The next morning my display was dead and would not come on. In the service manual it said to check current between pins 1 and 8 then 2 and 8 on the speedo connector. If there was 12 volts on both replace the speedo, if not repair wiring. It turned out to be the latter and after alot of looking it was a faulty circut breaker (they are under the front plastic in the black bags that are sealed on the wires). I just checked the current in and out of the breakers to find which one was bad. Then the technical part......I nailed it with a screwdriver handle 5-7 times and it started working again. Haven't had any trouble since. The only difference from your problem to mine is that when my speedo went dead my starter wouldn't work either. I would test the pins on your speedo first. Pin 1 is red, Pin 2 is red with white stripe, Pin 8 is Brown. This must be done with the key on."

 

your problems sound different as you lost function, his is flashing...it can be anywhere in the power/ground system, this includes fuses and fuse connections...

 

Mine are flashing, exactly 1 to 1 1/2 minutes after ignition.....It affects the entire electrical system....like his....I am gonna try his solution in a little while, otherwise I may just BLOW IT UP! LOL I'll let you know what happens.....Thanx for your help......

 

Found the problem.......Ended up being the Circuit breaker located under the front panel.....2 of them are under there, one for the cig lighter, the other must be for accessories.....It was corroded and extremely hot! smoking up and all.....once I replaced it, no problems......Thanks for all the help