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JacobSlabach

2004 Polaris Sportsman 500 Reversed Terminals On Battery

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20 hours ago, johniii said:

Ok just watched a video on youtube on the 03 sportsman there are two circuit breakers under the front access panel . Google :How to test circuit breakers on Polaris .

Sent from my SM-G965U using Tapatalk
 

I dont see any circuit breakers.

20 hours ago, johniii said:

Ok just watched a video on youtube on the 03 sportsman there are two circuit breakers under the front access panel . Google :How to test circuit breakers on Polaris .

Sent from my SM-G965U using Tapatalk
 

I dont see any circuit breakers.

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Here is a link to a site with the service manual  for the  2005 Sportsman 500. It won't let me  download the manual unless  I  sign  up  with the site so  I'm  just posting the  link for you to  do as you wish.. You can  view the entire manual  online ,  just can't  download it .

https://www.scribd.com/doc/51630928/2005-Polaris-Sportsman-400-500-Service-Manual-NoPW

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I dont see any circuit breakers.


Sent from my SM-G965U using Tapatalk

Looks like this but its sealed in a black plastic vag.

Sent from my SM-G965U using Tapatalk



images.jpeg

Sent from my SM-G965U using Tapatalk





images.jpeg

Sent from my SM-G965U using Tapatalk

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looked all throught the wiring harness, saw neither black bags or those breakers...  I got the new ecm in and now the lights and starter work.  The pod is still not lighting up with the key.

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Check the ignition, it’s possable that the contacts inside the ignition burnt up a little bit. See if you have voltage coming into the ignition switch and not going out when it’s turned to the on position.  

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the switch appears to be good, the lights and everything works like it should when turned on, and I took the switch itself apart and nothing looked abnormal...no black tips or discolored anything.  

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nothing has power on the pod cluster.  the headlights and taillights work, the starter cranks, I'm not sure yet if the stater works, but I got a new one sitting ready to go in.  I'm planning on trying to start it monday.

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You are going to test the stator first and also the regulator/rectifier, secondary etc. unfortunately you have to go through each item with an multi meter/ohmmeter. Then hope the cdi is not fried as well. 

 

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update:  I got everything back together (had to replace the carb) and this morning went out and turned the key and bam, on pops the display and the needle on the speedometer moved up to 0mph.  Dunno what changed between today and yesterday, but the display pops on every time I turn the key. now I have just two problems.

  1. It cranks but refuses to fire.  I checked that the gas was on, checked spark, changed the sp, let it air out, tried again and still nothing.  It was acting like it either wasnt getting fuel, or flooding out.  I know it runs cause I got it started in AL right before I switched the battery terminals.  (The float was busted in the carb causing it to leak so thats why I got a new one.)
  2. The back shocks had been replaced with aftermarket longer shocks lifting the back end but nothing was done to the front.  I bought a front end lift kit for it and put it on.  I looks much better now, but the front right axle feels like its binding up when I roll the bike.  The front left side bounces up and down on the shock but the right side is rigged.  I have never worked with axles before so any help on getting the axle in again would be great!

just a 2in lift in the front btw

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One thing you have to be aware of when lifting anything  with axels and universal joints is when the angle changes  on the universal joint it puts Pressure on the joint and or could cause it to rub/grind.   For instance if you put a lift kit in your truck you would have to slightly rotate your axle to accommodate the body being raised up. The angle/degree changes with the lift.   So it’s possible that’s causing the problem with noise or resistance.  

As far as the engine not firing you said you have spark and fuel ? How’s compression? Any blockages in the intake manifold? 

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I might not be getting any fuel in through the carb because when I took out the sp, it was completely dry.  No blockage in the manifold.  As far as the axle goes, I pretty sure it just popped out (but is still in the boot) because I accidentally dropped the strut on that side when I disconnected the shock.

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That would be good on the axle.  I would think then it’s just a matter of lining up the splines and sending it in.  Maybe get the front end off the ground and try it.  

Spray some carb cleaner into the carb see if she fires up a bit. Then you will clearly know it’s a fuel problem.   

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I tried starter fluid in the air filter (just a little cause I know how that can blow the head off an engine lol.....  nothing- but that was with the old sp-  I can try again with the new sp.

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I took the gas line off the carb and it was almost dry..  I cycled the engine a couple times and nothing changed.  I replaced the fuel filter and still no gas comes out the line (had the fuel valve on the whole time)  I think somethings up with the fuel pump, but the bike started before I screwed up the electrical.

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So try to gravity feed the carb. Hook a hose up to a small funnel or tank and to the carb and hold it above the carb and see is that works.  

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thats kinda hard to do since the tank feed is about 4 inches lower than the carb

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Yea I know but I always keep a small gas tank from a lawn mower and a 2 foot piece of gas line in my garage. I use it for things like this.  It’s a good item to keep around. 

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oh i didnt think about that..  I got an old minibike gas tank I could use.  Another thing- its stuck in high.  It seems like the shifter is jammed, so I was hoping that if I got the tranny turning, it would loosen up and shift out of high..  Its gonna be fun trying to feed gas in the engine with a high idle in high with a jammed front axle  :shocked:🤔👍

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I tried...  My jack (dad's jack)  is almost shot and only lifts half way up, and the bike is on a slight incline causing the jack to tip when the wheels come off the ground.

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