Hello
Just got my 04 Sportsman going for the first time in a few years. I had to purchase a new battery. Problem is, the battery light flashes and it will only idle with the choke out. If I turn the key on the dash will light but if I put the headlights on they do not come on and the dash will go out. I am only working off the pull starter. There is only 340 miles on it. Any ideas?


Edit:
Ok, battery is fully charged. It is a brand new battery. Nothing at all works, no power. Checked and cleaned battery cables and ground on frame. It was running but it would not idle, now no power at all. It started just fine the first couple pulls and I was getting ready to change the oil. Its odd that it started fine after years of sitting and now after running it a while its acting up. After running it, it gradually started to act funky. No idle, the lights would not come on and when I did flip the switch for the lights the atv would die. It would backfire so I figured just needed a tune up. It was sitting for years in a garage and I just decided to get it going again. Any ideas?

 

Could be an ecm by the way it sounds. Even if it's been changed under the recall,I've replaced multiple ecms on the same machines.Couple of the functions is charging back to the battery,fan operation,plus has a couple internal circuit breakers.Huge ATV Recall by Polaris - Sportsman and Scrambler
BUT it may be as simple as a shorted sealed circuit breaker located up from the battery or even the one under the front panel causing the loss of power to the ignition,lights,etc. #1 and #3 on the parts list. Just slice the pouch open on the rear breaker,if corroded,you can get this 20 amp breaker at any auto parts house. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

Thanks for the reply. I will look for the circuit breaker tomorrow. I am not familiar as to where the circuit breaker may be, so I will investigate. My atv is not under the recall according to my vin.

 

If that's the case you may just have the regulator/rectifier "IF" you don't have the big finned module under the front panel.AA models didn't have one.
Again a regulator/rectifier can go out also if the battery isn't charging,but the circuit breakers would be the likely cause if you have no power to the ignition,lights etc.Check these out first.
Again #1 and 3 on the breakers,#28 is the reg/rectifier.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

Great thanks again. Not to confuse you but I cannot find my atv on the recall but I do have the black finned module.

 

Okay... Just because it wasn't on the list doesn't mean that you wont have problems! 330 Polaris models weren't on the list either,but I had to change several Chinese black finned modules out. One thing at a time though. Check the circuit breakers first. You can even jump over the main 20 amp breaker to get temporary power just to see if it will start,then quickly check charging at the battery. Should be 14-14.5 volts. If it just shows battery voltage,the ecm will need to be replaced also. Even these modules have been updated!! Item #29 on the parts list..Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

I will check it out. If my atv has the ecm I thought the circuit breakers were built into that. I could be wrong

 

Click on the link I posted. Still shows both the fan breaker and main circuit breaker along with the ecm module,BUT during this time of changes to ecm modules from reg/rectifiers, the parts list may not have reflected this,plus I sure can't remember everything about all the machines Polaris has made! That's why they made manuals for each year model..

 

Ok, I cannot find circuit breakers anywhere! I am thinking they are in the ecm. On the link you posted where exactly are those breakers located? The picture is very grainy.

 

If there are TWO,one would be up from the battery,tucked up under the left rear fender on the frame. The other is under the front rack and panel for the fan.Shows two on the parts break down,BUT again parts lists can be wrong since 2004 was the first of the reg/rectifier to ecm change over years.Ecm basically controls charging,fan operation,battery protection circuit(don't think so plus controls accessory power and also hot lamp control,plus circuit breakers depending on year model.