My son and I were riding the other day and all of a sudden, his machine just died. All electrical went out. He re-started it successfully and we took off, but the same thing happened 4 more times on the 20 minute trip home. This machine has about 300 miles on it ....anyone have any suggestions?
Thanks and Happy Holidays!!

 

My guess is a circuit breaker is tripping, you may have a bare wire shorting out or the breaker itself could be bad from water intrusion/corrosion. Check your manual for the breaker location but I think they are under the front hood in black plastic pouches.

 

i agree with powerslider, it's the circuit breaker under the front hood. Also will help with u clean off the battery terminals.

 

Hey Bigjer,
I have a 02 700 twin and it did the same thing. After the circuit breaker under the front panel (to the left, that is in a black watersealed pouch) cooled down, it would be fine for about 5-10 minutes and then the electrical would cut out entirely....Check the breaker for corrosion, after I replaced the voltage regulator, cylinoids, and light switch on handlebars (overall $250.00) I ended up fixing the problem with a $20.00 circuit breaker even the dealer couldn't figure out...LOL good luck.......

 

I bought a replacement breaker at NAPA for CHEAP!!! compared to the Polaris Shop. It was exactly the same. At the Polaris Shop they wanted $35 CAD and at NAPA it was $7 CAD.

 

Thanks all...I will tear into it later.....I'll let ya know how I make out.

 

Good Luck....have fun.....

 

ok...had a chance to look into this some.....found nothing obvious except accumulation of dirt around voltage regulator plug. Haven't had a chance to test drive . I have a couple questions...
1. Where is the circuit breaker on a 2004.5 sp500HO ? and what does it look like?
2. does the supply side of fan connector plug always have 12-14 volts to it when unplugged? mine does..with no fan run, but 12v applied to fan side of plug runs the fan.

 

The breakers are under the front hood I believe in black plastic semi-sealed pouches, check your owners manual-it should tell there location.

The fan I can't say for sure without a schematic but it's very possible that the fan motor is fed 12v and the ground side is run through the temp switch in the radiator....

 

I have looked closely under the hood.....can't find any "sealed pouches" or anything that resembles it.
The owners manual is next to worthless.....metions circuit breaker once in "troubleshooting" but doesnt give a clue where it is located.