Hi Guys, Alright here is what I have. NEED HELP..
2004 Sportsman MV7 (IE 700)

Problem: Owner decided to pull the fan plug (12volts) because the fan wouldn't stop running and now the machine has NO power past the Voltage regulator and the starter solenoid.

12 volts takes 3 paths from the batt.
- 1 cable feeds the starter solenoid. (has 12 volts on the batt side)
- 1 cable feeds the 2 winch's (which I disconnected for trouble shooting purposes)
- 2 smaller wires to the Voltage regulator

12 volts isn't found anywhere else on the machine. However the ignition switch has around 5 volts but isn't enough to kick the starter solenoid.

Trouble shooting steps.
- Battery is brand new but I charged it anyways and verified the voltage and cranking amps. (IE starter solenoid bypass) Starter turns over perfectly but quad doesn't start. Good
- Tested the starter solenoid. Good (No 12v switch signal from the ignition but will switch with external 12 Volt source).
- Tested the starter. Good (bypassed the solenoid)
- Tested the Run switch. OFF/ON/OFF (ohm meter)
- Tested the ignition switch. Good.
- Tested the thermistor which connects directly to the voltage regulator. It was Bad. IE 2.5K omhs at room temp. Replaced with new sensor. Still no power. Now 1.2K ohms at room temp. Might be why the fan was always running.
- Still no 12 volts past voltage regulator. Tested all outputs from the voltage reg and found no 12volts out.
- Checked my grounds and didn't find any problems. Good.
- Cabling. Looked for a voltage drop issue but couldn't find any. Good
- Traced out the 12 v lines from the batt to the voltage regulator and found no problems.

The voltage regulator has 3 connectors
1. From the stator. 3 yellow wires.
2. From the thermistor. Thermostat from the cyc head. Temp probe.
3. 10 pin connector which seems to take 2 / 12 volts lines and distrube them to the machine. IE ignition, lights, speedo, ECT.

Pretty sure the problem is the voltage regulator but this isn't my quad and I don't want to waste $$$. Any other ideas before I buy the regulator?

Thanks a million,
Tim

 

i jsut had a starter problem to and it wa that a bearing sessed in the starter around the starter shaft so it woudn't turn. does your machine turn over or does it make a clicking sound.

 

Hi, Thanks for your input but the starter is definatly good. I by passed the starter solenoid and starter turns over perfectly. I was hoping the machine would start with the solenoid bypassed by it doesn't get spark and again no voltage past the voltage regulator.

Got to be the regulator. Mainly because it's getting the input from the stator and the batt but nothing is coming out.

Tim

 

There should be a fuse block under the front rack and plastic, check all the fuses, Ive also seen wires puled apart at the fuse block, there are 2 screws that mount it to frame, take them out and look at the backside too.

 

Can't find a fuse box and there isn't one listed on the electrical diagram. Do you know for sure there is a fuse box? I will check it again

 

if the fan was on continuously i would suspect the ecu went bad causing your problems. there was a recall on them. might do some searching with your vin number to see if anything comes on on recall lists

 

I second the ECM as a possible problem.

 

Hi guys,
Good job guys it was the ECU also called the voltage regulator on the wiring diagram. And there was a recall so the part was free. Wish Polaris would have told me this Friday so i wouldn't have spent the weekend verifing the rest of the electrical.

Thanks for the help,
Tim from New Hampshire