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Old 10-12-2011, 02:12 PM
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Just got used 1997 Polais Sportsman 500 and now electrical issues

I just picked up a low mileage 1997 Polaris Sportsman 500 with 450 original miles. I am having an electrical issure, the starter, headlights, and winch all stopped working. It will run when I manually pull-start it. Does this machine have a fuse box or what would be a good place to start looking for issues? I am really mech. inclined, but never have worked on a four wheeler. thanks
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Old 10-13-2011, 04:05 AM
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The fuse box is a good place to start looking. Go to the Technical manual section of this site and download the manual for your model and year. Read it carefully. You will find the loaction of the fuse box. Look for common areas of the starter, headlights and winch (read battery). Take apart whatever is holding all of those wires together and check everyone of them from start to finish. Repair or replace any damage that you find. Look closely at the connections of those wire. Remove any oxidation that you find by whatever mean are at your disposal. Take lots of pictures of how everything came apart so that you can put it all back together with an emphasis on not creating any new problems. Don't worry! You'll figure it out!

jake
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Old 10-13-2011, 05:33 AM
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Old 10-13-2011, 12:37 PM
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Thank you for the invite. Ok I measure the battery and its about 11.48 volts. I cant seem to find the scematic of the wiring. Where you be a good place to start looking for the fuse box? I hear a click from small rubber covered electrical piece on the clutch side. It has a small red wire to it and out of it. thanks
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Old 10-14-2011, 11:10 AM
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I have a '09 Sportsman 500 HO. My fuse block is under a rubber cover inside of the front cargo box, near the radiator fill. I have read someplace that charged a charged battery should read 12.8 volts, however I suspect that the battery is not your trouble. You are really going to have to dig into a tech manual for this machine for more concrete answers.

Jake
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Old 10-14-2011, 12:23 PM
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These years don't use a fuse box only 3 circuit breakers, I have a 1996 which is the same thing. I have the complete service manual in pdf if you want it just let me know your email address. The manual i have is for 96-03 and as far as i can tell they didn't put a single fuse in a sportsman till 02 and from what i see its only for the 12v accessory connector.
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Old 10-15-2011, 09:52 PM
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My email is jjrightmire1973@yahoo.com. I looked under the plastic under the light and front rack, but it has wires everywhere.
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Old 10-15-2011, 10:48 PM
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I remember my father in-law telling me not to run the lights if my battery was low/dead as it would blow something in the electrical circuit. He had to replace a few breakers or such when that happened to him.
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Old 10-16-2011, 09:33 AM
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Ok I got the winch, and stater working. The winch silonoid grounded out on the case casueing the breaker to trip. I found the circuit breaker and the bike now starts and runs, but no head lights. The switch and lindicator lights work for the head lights, but the head lights themselves dont work. Is there a fuse in the plastic cover in the center of the handle bars? I have power to the switch but no power to the head lights. thanks
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Old 10-17-2011, 06:50 AM
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Nope no fuse in there or anywhere on our machine, unless they didnt put it in the manual for some reason. unfortunately this manual is about 60 megs and yahoos limit is 25.. we aloud to post links to like rapidshare on here?
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