I recently rebuilt my 2000 Polaris sportsman 500. After it was all put back together I realized the battery was dead so I hooked it up to a charger and went ahead with trying to break in the new rings that I just installed. with the battery hooked to a charger I tried to start the four wheeler and it started ran for a few seconds and died. After it died the battery didn't have enough juice to turn it over so I let it charge a few mins and tried again it turned over a few times and then it wouldn't do anything. The lights or nothing will come on anywhere. Its like it blew a fuse or something but I cant find any fuses on it! The battery was very hot from the charger running so I left it alone and ordered a battery. I'm puzzled as to why I've lost all power to everything if there is no fuses... Any help would be greatly appreciated!!!!!

 

Get a new battery!!! The circuit breaker is in a sealed pouch up from the battery. Check that you have 12 volts going in and out. If not slice the pouch open and check the breaker connectors. Probably shorted out. You can get this 20 amp breaker at any auto store for a few bucks.

 

Ok thanks. Battery is on its way. I checked the fuse in the sealed pouch and it seems to be fine so hopefully the new battery will fix it!!!

 

These are resetting or what they call thermal breakers and can trip. When they cool down from loads(starting,getting hot from jump starting,etc) they can reset. Better than popping blade fuses when they work right. After so many years though most do get corroded even in the pouch or short out. You can usually still pull start this model with just the key on in an emergency even if you have no power to the dash,lights,etc. But not advisable as bulbs can blow and in some case other electronics can be affected since the voltage from the regulator has to go somewhere if the battery can't accept it. Bulbs offer the least resistance and first to go.

 

I did not know that! Thanks for the info!!!!! My new battery should be here middle of the week when I get it in I'll update the thread. Thanks