Just got used 1997 Polais Sportsman 500 and now electrical issues - Polaris ATV Forum
Polaris Sportsman Discussions for the Polaris Sportsman 90, 300, 355, 400, 450, 500, 550, 600, 700, 800, 850

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 13 (permalink) Old 10-12-2011, 03:12 PM Thread Starter
Junior Member
 
jjrightmire1973's Avatar
 
Join Date: Oct 2011
Location: Crockett, Texas
Posts: 6
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
jjrightmire1973 is offline  
Sponsored Links
Advertisement
 
post #2 of 13 (permalink) Old 10-13-2011, 05:05 AM
ATV Enthusiast
 
vajake's Avatar
 
Join Date: Oct 2011
Location: Virginia
Posts: 78
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
vajake is offline  
post #3 of 13 (permalink) Old 10-13-2011, 06:33 AM
Polaris ATV Legend
 
Bruce!'s Avatar
 
Join Date: Feb 2009
Location: Port Angeles WA
Posts: 20,004
Welcome to the board!

I tried setting my password to "penis" but it said my password wasn't long enough...
Bruce! is offline  
Sponsored Links
Advertisement
 
post #4 of 13 (permalink) Old 10-13-2011, 01:37 PM Thread Starter
Junior Member
 
jjrightmire1973's Avatar
 
Join Date: Oct 2011
Location: Crockett, Texas
Posts: 6
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
jjrightmire1973 is offline  
post #5 of 13 (permalink) Old 10-14-2011, 12:10 PM
ATV Enthusiast
 
vajake's Avatar
 
Join Date: Oct 2011
Location: Virginia
Posts: 78
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
vajake is offline  
post #6 of 13 (permalink) Old 10-14-2011, 01:23 PM
Extreme ATV Enthusiast
 
Bamper's Avatar
 
Join Date: Oct 2011
Location: washington, ME
Posts: 152
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.
Bamper is offline  
post #7 of 13 (permalink) Old 10-15-2011, 10:52 PM Thread Starter
Junior Member
 
jjrightmire1973's Avatar
 
Join Date: Oct 2011
Location: Crockett, Texas
Posts: 6
My email is jjrightmire1973@yahoo.com. I looked under the plastic under the light and front rack, but it has wires everywhere.
jjrightmire1973 is offline  
post #8 of 13 (permalink) Old 10-15-2011, 11:48 PM
Junior Member
 
Parky50's Avatar
 
Join Date: Apr 2011
Location: Colorado
Posts: 29
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.

Parky50
Colorado Springs, CO.
98 - Yamaha Grizzly 600
94 - Polaris Sportsman 400
Parky50 is offline  
post #9 of 13 (permalink) Old 10-16-2011, 10:33 AM Thread Starter
Junior Member
 
jjrightmire1973's Avatar
 
Join Date: Oct 2011
Location: Crockett, Texas
Posts: 6
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
jjrightmire1973 is offline  
post #10 of 13 (permalink) Old 10-17-2011, 07:50 AM
Extreme ATV Enthusiast
 
Bamper's Avatar
 
Join Date: Oct 2011
Location: washington, ME
Posts: 152
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?
Bamper is offline  
Reply

  Lower Navigation
Go Back   Polaris ATV Forum > Polaris Model Specific Discussions > Polaris Sportsman

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Polaris ATV Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
sportsman 500 electrical issues tim63 ATV Repair and Maintenance 2 09-11-2014 07:09 AM
'05 Sportsman 800 EFI - Electrical issues? Ivando2 Polaris Sportsman 4 01-18-2013 01:58 PM
1997 sportsman 400L carb issues/want to eliminate oil pump crmelectrical Polaris Sportsman 0 02-02-2011 05:32 AM
2002 sportsman 700 electrical issues OTS611 ATV New Members 2 08-16-2010 08:17 PM
2003 sportsman electrical issues.... mr novice ATV Repair and Maintenance 0 06-11-2010 06:52 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome