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I have been working on this problem all summer. My daughter has a sportsman 90 that runs fine, until the battery runs down. Then if I charge the battery overnight, it runs great again, until the battery dies again. I pulled the stator and had the shop test it. It was bad, so I replaced it. I charged the battery, it fired up, ran great. Yesterday I went out to start it and the battery was dead. I jumped it with another 12V battery. It starts and runs fine, until I unhook the "jump" battery. The second I pull the jumper cable, it dies. Any suggestions?
 

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replace your regulator rectifier. 0453479 is the part number for an 07 sportsman 90. there is no definite test for a reg/rec. you can only check the stator, the wiring, and the battery. if all that checks out you replace the reg/rec and retest to see if it's charging. so assuming the battery is good and the stator is new, and it runs with a fully charged battery, i can only assume the reg/rec is to blame.
 
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