04 500 Sportsman ho electrical problem - ATV Forum - All Terrain Vehicle discussion for Honda, Yamaha and more ATVs

lapg28 · 10-13-2009, 10:44 AM

Has anybody experienced electrical problems, such as lights,4x4 loss,and speedo loss happening then coming back on. Tried to find problem but not with any success!

toddster · 10-13-2009, 07:58 PM

a few things can be wrong, fuses being coroaded (as your troubles are related to the handlebar area (awd switch-lights+switch and cluster), or handlebar connection cut, they ty-wrap them to the neck of the handlebars...this was the problem on my 03 600....hope this helps in the search
keep us up with the progress

lapg28 · 10-13-2009, 09:04 PM

Looked at that,can't seem to find anything. But lights sometimes dim ,like a major drain on power,sometimes go out and then can come back on. Wonder if anybody has a wiring diagram. Thanks in advance for any help,and Thanks toddster.

Trikemaster · 12-02-2009, 01:50 PM

It is your ECM(under the high beam headlight mounted to the frame).
Some dealers might call it a "PDM".....Power distribution Module

Imo....#1 Battery or #2 ECM(Electronic control Module)

It has the part number Rectifier, Regulator, LR 390 for the charging system which controls the voltage. if you unhook the battery from the bike and check the volt output what do you have? when the key is off and you put the battery back in the bike does the cables spark at all? if so then you have a short somewhere which will drain the battery down. these bikes need to maintain at 12.5 volts to run. like the speedo display. if the battery is in the bike and its running, check the output voltage like at 3,000 rpms and it should be pushing up to 14.8 volts area, but not over 15 volt and at least 13 volts .
if not then maybe the recitifier is bad or the dead short is robbing all the power. Good luck

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Trikemaster · 12-02-2009, 01:54 PM

We need to get that beast shreddin dirt again

2004 Polaris SPORTSMAN 500 (A04CH50AA/AC/AE/AG) OEM Parts, 2004 Polaris SPORTSMAN 500 (A04CH50AA/AC/AE/AG) OEM ATV Parts - BikeBandit.com

Trikemaster · 12-02-2009, 02:02 PM

Allot of people are having the same problem as you. One guy replaced the ECM 3 times and it was fixed on the 3rd time. Some people have bought BAD BATTERIES right off the shelf from the store(brand new).

lapg28 · 12-02-2009, 04:31 PM

Thanks Guys, Hope I can help you one day