Took my 05 400 sportsman in for the recall on the ECM. Dealer puts new one in and says it's good to go. I get it home and it ends up doing the same thing it was before. Give it anything over 3500 RPM and the battery light flashes and the motor will die if you dont let off pretty quick. I checked voltage @ battery and it is clearly a regulator issue. 13-15 volts @ idle and goes up to 19 at 3000 rpm. I unplugged stator wires coming into ECM and I'm getting 22 volts a/c. Is that normal? It runs like a champ as long as the stator isn't plugged in and I'm just running off the battery.
I know they'll probably replace the ECM again if its just a bad replacement but want to be sure I'm not missing something that could be frying them. I would think they would have some sort of over current protection ahead of the regulator/rectifier in these units but maybe not. Any of you guys had to deal w/ this.

 

Make sure dealers techs reinstalled all 5 ground wires on right side of mounting screw and all connectors are tight. OPT

 

All connectors are tight. What did you mean by "Right side" of screw. They are mounted between screw head and body of ECM. Should they be under it between ECM and frame?

 

Does your machine fire back up right away after it shuts off?

 

Only if you turn it off and then back on. If you just roll to a stop and try to turn it from on to start you dont get anything.

 

Long as all (5) ground wires are mounted and tight,usually mount on top of ecm module on right ecm mounting screw. Have had a couple "new" ecm modules go bad also. OPT