Hey guys happy new year!! So this electrical problem has me at a loss. 2002 sportsman 500 HO with 700 miles (i bought it new) i went for a ride tonight and everything was perfect then i noticed my speedometer went out along with my AWD and my starter. My winch, headlights (not taillight tho), and little red dots on the left bar work though. I cant seem to pinpoint this one and my battery is fully charged and new. My radiator fan also works and when i pullstart it it runs fine. Its always garaged and i keep up on maintenance. Any suggestions?
2002 Sportsman 500 has me at an electric loss!
Cuzboss
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Thanks guys and latebird said from the negative side so put the negative tester side on the negative side of the battery terminal and use the positive lead on the tester to actually test the key switch correct? What should it read with the key turned?
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You should read battery voltage on the red wire with the key off, the same on the red/blk with the key on and the same on the red/wht wire with both the key on and the handlebar switch in the run position
Started at thr battery, then go to the fuse box check to see where you’re losing power. Grounds are just as important as hots. You may have lost the ground connection to the frame someplace or you’ve lost a fuse to the power distribution don’t throw parts at it. Use a meter, even if you have to get a $20 unit at Harbor freight and diagnose it step-by-step until you find where you have lost power
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I have a 2002 500. The attached manual is what I use as a resource. As someone who has been in electrical, electronics and fiber optics for 40 years I agree with the gentleman who advised you check all connections with a test light or VOM, clean, recrimp, check wire continuity and the presence of voltages.
Good Hunting
Good Hunting
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Left handlebar Kill switch on?
Years ago my 2000 500 sportsman suddenly failed the 4wd light, and had only rear wheels, after a lot of searches I found that there was a situation where if you tried to start with a dead battery using the pull start, it would burn out a couple tiny resistors inside the analog speedometer. Sure enough, I replaced the resistors and voila! Awd worked again. I was told not to try and pull start with a dead battery, this was five years ago, has worked fine since….just something to follow up with….
It was kind of a pain to pry open the speedo, but from there, my EE buddy soldered in a couple tiny resistors and all fixed
It was kind of a pain to pry open the speedo, but from there, my EE buddy soldered in a couple tiny resistors and all fixed
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Wasn't that much easier and faster than poking around and guessing?
Glad you got it Cuz.
But isn't that the purpose of the recoil starter?
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The purpose of the recoil starter is for when the battery is too weak to start the engine or the starter circuit fails - if the battery is completely dead or disconnected it will still start and run, but may burn out DC accessories - if you want to start and run with a dead or no battery, disconnect the rec/reg.
You guys are awesome! Starting with a pull start is sort of a last resort backup type of thing, if the battery is dead it should be replaced because it isn’t meant to run with no battery voltage. I refuse to get a new Sportsman for the reason that there is no pull start and if i get stuck in BFE im screwed hence why i try and keep mine as new as possible.
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