I'd like to start by admitting that I'm far from a mechanical master, actually more like an apprentice. I have a 99 Sportsman 335 with a whopping 207 miles on it (although this is yet another story). I'm trying to get back to a point where I can ride again. I took the bike to the shop about 3 months ago and asked that everything be checked out. I was pleased to be told the only thing it needed was the fluids changed and a new battery. Everything seemed fine for about 2 weeks, then because of schedules, I wasn't able to ride for about 2 weeks. Now the brand new battery is dead once again. I've talked with a few local riders and have been told i need to replace the stator and the ignition coil. I broked the spark plug wire yesterday trying to replace the spark plug and bought a long boot performance max plug wire, traced it to the ignition coil and put everything back in place while charging the battery, and my son was really hoping to ride, but once again, no go. The problem really started about a year ago riding at decent speed, or with the high beams turned on, the bike would start to spit and sputter and lose all power. I'm at the point where I have no idea where to start. Any guidence or advice would be more than greatly appreciated.....D

 

first thing is there any spark? if so then the battery should be tested to make sure it has 12.5 volts. when you start it make sure its reading at least 13 plus volts w/ it running. if it isnt, chances are the recifier is bad. this controlls the voltage to the bike. let us know. oh btw if the battery is weak the bike start to run crappy as you stated w/ the high beams on. the more the battery drains, then the worse the bike will run. it should be at least 12.5 volts.

 

I would look intro the stator, next I'd prolly check the stator and if that's not it check the stator........hope that helps

 

So, Squeege, if I'm reading and understanding correctly, you believe it's probably the stator. I'm hoping to have time tonight to check it and from stendori reply, the rectifier. Now, for the important question - how does one go about testing/checking a stator, and I won't ask the question about where in the heck the stator is. Thanks for the help so far...

 

Actually I thought this was a 90cc Polaris problem that you posted......I'm sorry

here is what a breakdown for a 90cc looks like............just a general idea of main parts you might see in a stator assay.

 

okie now isnt this a sm 335 not a 90?????????? i just wnat to make sure we are talkin about a sm 335 not a 90??? or are we???

 

I haven't had to check my stator yet, but It sounds like you might have a stator problem.......If it's not to hard to get to it, I would check yours out and clean it up with electrical cleaner.........Any old quad/motorcycle manual might have enough info to get you pointed in the right direction(you should invest in one)

 

slonez, it sounds like something is shorting out. Do you have a volt/ohm meter and know how to use it? Do you know where the voltage regulator is on your bike? The voltage regulator is in front on the radiator on a 2002 Sportsman. If you can find the voltage regulator, let me know how many wires and what color.

Also, the ignition is like on a lawn mower. It does not need 12 volts to run and it is shorted to ground to turn it off.

 

check all the wires under the headlight pod between pod and front console cover seen a lot of broken ones there, sounds like you have a short somewhere. good luck

 

ohh also do an amp draw test, unhook the neg from the battery and hook your multimeter set on dc amps from the neg battery post to the neg cable lead that goes to battery, you shouldn't have any more than .001 amps dc.