hi guys,

i just bought an '02 sportsman 400 which has a couple electrical probs. ive already found that the starter solenoid is bad, but the pullstart works easily enough. after starting, quad runs and idles perfectly. the prob is that the digital gauge flashes 413 for a few seconds, the speedo needle flashes, and then fades to nothing. the lights do the same until revving at a higher rpm to make them brighter, then they dim again as slows to idle... kind of like an alternator that is almost gone in a car.

this is the first atv ive owned so any help is appreciated.

 

will a voltage regulator cause these issues?

 

Get a multi-meter and check the voltage at the battery with it shut offf, then start it and rev it up a bit and see if its charging, should have 12 volts with it off and 13,5 or more running.

 

I have seen voltage's swinging all over the place when the voltage regulator goes bad - so I would guess that it COULD cause the problems noted. The first thing I would check is the voltages as Kerbbirds suggests.

 

replaced the starter solenoid, still no spark thru it when i turn the key though, im guessing there is an inline fuse or my ig switch itself could be bad i guess... i also noticed that the switch seems to be routed through the reverse/override button on the handlebar to disengage the rev limiter??

tested voltage:

12.4 VDC when off

12.4 VDC at idle...

12.4 VDC when revved..........

 

CHEAP TEST, CLEAN ALL YOUR GROUNDS.

 

Remove the front cover and check for broken wiring. Somewhere arond that year I found several Sportsmans that had broken wires. A couple brown and a yellow usually. The way they are routed and wire tied causes them to break/cut in two. Can cause exactly what you describe. You'll have to open up some of the plastic looms to find them.

 

cleaned everything with a toothbrush. checked grounds for continuity and wire condition with body and wire covers removed, everything looks good. the orig owner replaced the battery a couple weeks ago with a brand new one. i havent gotten my owners manual in the mail yet, so im not sure where to proceed next.

 

well, apparently the voltage reg and the ignition switch are faulty. the root cause may be the 20 amp breaker i found coming off of the battery. the pouch that it was sealed inside was full of water, and the breaker almost rusted in twain. im guessing with no breaker and conducting through water was enough to fry the regulator and switch. im hoping these are the only two parts in the electrical system that have been damaged....

 

jeebus cristo!

well, evidently the person who wired the starter solenoid up the last time it was worked on before i got it placed the hot on hte wrong side .... wire switched, everything runs perfect.