I have a 2004 Polaris Sportsman 500ho and having issues with the NEW battery not staying charged. Was having the same issue with the old battery. I replaced the battery, starter, and solenoid about a month ago. Every since than, I have to charge the battery about every 2 weeks. I believe it's the regulator but when trying to get a new one, none of the ones I've found don't match what's on the quad. Anyone have any suggestions on the issue with battery not holding charge?

 

Three 2004 model 500s had ecm modules that were under the recall. Sure you have the regulator or the finned ecm module? If you do have the regulator mounted by the radiator,the part number supercedes to 2203638. Ebay has them for 99 bucks. You might check around to see if you an get a better price.

 

It has the regulator mounted by the radiator. Thanks for the information. I'll see if that works. I know that they had different production year models for 2004 but didn't realize that they had recalls on ecm modules.

 

I think they were on the 04.5 years as they were on the 450's that same year. feel lucky that you have the older type which has less issues for the most part.

 

Yea it was these three odd ***** that had the ecm modules.
2004 SPRTSMN 500 A04CH50AO
2004 SPRTSMN 500 A04CH50AR
2004 SPRTSMN 500 A04CH50AS
The 450s were all 2006 models.When we got the first tech bulletin no mention was made of any model other than the 2005 500. Later on other bulletins came in and added more to the crap I had to deal with. Plenty of early 330 models also had faulty ecms,but weren't included on the list.Customers had to pay up front for these. Before we had the "official" recall Polaris sent all dealers a tester that we used to put a load on the Chinese modules. If they passed,we had to put two green dots on them for future reference sent them back out, just replaced the ones that failed the load test.. Then after doing a bunch of these over a span of about a month,got the bulletin to replace them all.. I had to contact customers again to make sure they could bring them back in.Guess that's the main reason I love regulators..The simpler it is the better is is.

 

Found the issue. My brother-in-law (not a mechanic, lol) was trying to fix main headlight and just started unplugging wires. He ended up unplugging one of the wires to the regulator. Also, ordered a new one since the old one has a bulge to it.