just make sure to add the acid and then wait at least 30 minutes so the acid soaks into the lead plates. will extend the life of battery and if you have it fully charged before using it. imo.

 

Holy crap guys, the regulator/rectifier is like 100 bucks! Any good places on the internet to get it from. So far,I found one from cheapcycleparts.com and they have it for like 77 bucks.

 

I never said it was cheap.

 

So, I got my wheeler back together and running. I put a new voltage regulator and battery in it and it seems to be good. I tested the voltage and I dont think it even gets to 15 volts anymore. Very pleased with that. I do have one issue though. There are 4 connectors for the regulator, 2 I was able to get in and crimped together nice and tight, but the other two not so much. the two that I couldn't get were the ones that go by the headlight into the black connecter deal. Any suggestions for that? the other thing I'm having an issue with is getting the throttle adjusted right. The only time it cuts out (etc activating) is when I let off the throttle and bump it back with my hand. If I just let off of it it is fine, but if I push it back further it shuts off. How can I get that fixed?

 

As for the throtle sticking, I need to see it before I can say anything. On the electrical, what colors are the wires and are they coming off the regulator? You are right. there is 4 connections. 2 of the wires are the input for the regualtor and the other 2 is the output. I might have to go look at mine so I can tell you which one is which as long we have the same colors.

 

it sounds like you need to adjust the throtle linkage there was a post on this a week or so ago with alot of people haveing there atvs shut off becuase the throtle goes to low when they let off the throttle.

 

just adjust the cable so there is about 1/8" play and it should be fine.

 

There was a red, a brown, a yellow, and a yellow with a red stripe. The two that don't have very tight connections are the red and brown. I'm going out trail riding tonight, so hopefully everything is ok. I had it out last night and everything seemed ok.

As for the throttle, I do have about 1/8" of free play. The issue is, when you let off of it..even just bumping it with your hand will activate the etc. That is the only time that it does it.

 

I just had this kind of problem with with my 2005 600 sportsman replaced the battery. found out the starter bearing had rusted and seized. It would start when the battery was newly charged but then quickly seemed to run dead. Teh bearing was 5 bucks new 0ring and some silicone and it seems as good as new. Couldn't tell the starter was bad till it was fixed starts like new. Don't know where the moisture came from there are 2 o rings that seal the starter to the motor.

 

I just had this kind of problem with with my 2005 600 sportsman replaced the battery. found out the starter bearing had rusted and seized. It would start when the battery was newly charged but then quickly seemed to run dead. Teh bearing was 5 bucks new 0ring and some silicone and it seems as good as new. Couldn't tell the starter was bad till it was fixed starts like new. Don't know where the moisture came from there are 2 o rings that seal the starter to the motor.