I have a 2004.5 Sportsman 500 that doesn't seem to want to stay running. It starts and idles fine but when I take off it will tach up to about 4000 and die out like I hit the kill switch. Also when it revs up the battery flashes on the speedo. Earlier this winter I almost killed the battery trying to start in sub zero cold but it finally started. It did the same stalling thing until I put it in a garage that was warm for about an hour and then it ran fine, but the battery light flashed under a load. I ran dry gas through it and it seemed to run ok. When I ran it this weekend it was in the 40's so I can't imagine the fuel was frozen but would a low battery cause it to die out? My friend has the same machine and his battery is dead all the time but it runs fine so I don't know what to think. I charged the battery but haven't had a chance to re-install it yet. Would water in the fuel cause it to die without any sputter at all? Any help would be appreciated.

 

here is a few ideas
airbox and filter must be on it when testing(that caused my 330 to die out at hi rpms)
check voltages at batt should be around 13.1v
pilot and bottom jets are for idle, main jet is for 1/4 throttle and above
change fuel filter, test pump(at vacumn pulse side should maintain 5 INCH lbs
if you have a specific question i have a 2003 factory repair manual for 330 and 500

as i said i had a very simular problem but it did it in neutral also, had it only done it in gear someone told me it might be clutches
p.s these batteries cannot take a high charge, i would reccomend 2 amps only

 

just a thought,this year 500 came with a factory defect. the spark plug wire was pinched between the body and chassis. mine showed some of your symptoms

 

make sure when its running at a higher idle to check to see if your at least putting out 13 plus volts coming to the battery. if not then maybe the recifier is going bad. they do ned to maintain at least 12.5 volts to run correctly.

 

Thanks for the replies when it warms up outside I'll check it out. If it is in neutral or park I can rev the hell out of it and it doesn't die out. Hopefully it is bad fuel or the filter is crap. I charged it on 2amps so the battery should have taken it alright.