[kmpville1965]

I just bought a 1997 Sportsman 400 with only 2500 mi. It definitely needs a new battery. It also appears that the charging system is not working. The 4x4 does not lock in when the button is pushed in and no lights work and I don't think the cooling fan works either, but I don't think I've gotten it hot enough to turn on the fan. I am an electrician by trade and am mechanically inclined, so I have the ability to do some trouble shooting. I need some help finding the fuses and relays. Does all the plastic have to be removed to access these components? Can I get a wiring schematic for this machine? Any advice, tips, or help is appreciated.
Also it's going to need some brake pads soon, where can I buy parts that are reasonably priced?

 

[stave7119]

You can get a Haynes manual for the sportsman which will include the wiring diagrams or a digital copy of a repair manual which will have them. Personally I prefer a paper copy, but I do have digital copies of a few manuals too. As for parts, you can pick up parts from a number of sources. Ebay, bikebandit.com or fixmytoys.com are just a few.

Electrical problems can be a real pain to diagnose sometimes. Good luck with the machine

Steve

 

[Hydrex]

Welcome to the forum. I have a 98 Sportsman 400 with 1,300 miles. My mechanic is going over it now. Had to replace the fan, found out the oil injection was not connected, yikes! I charged the old battery after filling and it seems to be holding a charge. Make sure you fill the battery with water before charging .

 

[kmpville1965]

Well, then electrical troubleshooting was not too bad. I found that there's a switch in the gearshifter that is open in neutral. Mine seems to be slightly out of adjustment is High range. I'll check out the adjustment procedure for the switch. Thanks for the replies and the welcome.

 

[sportsmanrider500]

Yeah, get a manual and you will find it a lot easier to troubleshoot. Good luck and welcome!