My wife's 2004.5 Sportsman 500 H.O. has developed an electrical problem where the fuel gauge doesn't work and the battery won't charge. Also, if the reverse override button is pushed while using the winch to lift the plow, the engine is killed sometimes. Any suggestions?

 

Did you get a new Electronic Control Modules (ECM) from Polaris recall,it makes many electrics go screwy when it starts acting up. Here is a link.

Polaris Industries Expands Recall of ATVs Due to Fire Hazard

 

It also may be that you have to much of an electrical load on the system. Do you have any other accessories running? High wattage lights? Stereo, hand warmers, etc?

 

Thanks TLC. Our model is on the recall list, but we were never notified by Polaris back in 2007-2008. The local dealer was reluctant to deal with this since the recall was so long ago, but they will be looking at the machine in the next couple of days. I hope this clears up the electrical problems. Again, thanks for info.

 

bcdudley, we don't have anything special on the machine. The battery failing to recharge and the fuel gauge not working started last summer. I noticed the engine quitting when the reverse override was pushed along with the winch recoil button started after installing a Warn RT3.0 winch about 2 months ago.

 

I would get the ecm fixed before doing any further troubleshooting for sure if it is on the recall list. I only mentioned the extra accessories because to much load on a stator can cause the engine to die.