Is it the stator?

[kywest]

Here's the deal. Working on a buddies 05 Sportsman 500. When I got it, didn't run at all. Have it running now but there is still an electrical issue. Half the time everything works from the turn of the key. Then eventually the display will go out, AWD stops working, lights go out, winch won't work, motor runs very rough. Once the wheeler dies, it'll still turn back on but the display will not work. When the display is not on, if I turn on the lights it kills the engine. I originally thought there was a ground issue but I've torn apart the wiring looking for any abnormalities. Nothing found. Battery is good. No clue where else to look other than the stator. Anybody got any other advice or places to check? Thanks guys.

[Shorty54]

What is the voltage at the battery before you start it? After it is running at idle? Reving it up? Could be a charging issue, which could be related to the charging side of the stator. Does that year have a Surefire module on it? I have seen those fail, but then you usually wont have spark. Make sure you clean and dry all connections, I like to put die electric grease in them after they are clean. These new machines and their electrical componets dont like moisture very much. good luck.

[Gordie]

Check the wiring harness I bought a 06 sportsmen and I had to replace the wiring harness. The connectors under the headlight assembly were all corroded most of it was in the blanked off ends that tied the wires together. Also check the battery cables corosion will eat those up inside the cable sheath .

[CFRay]

I have an 06 450 Sportsman. Similar but not identical issues last fall, would not start, even with pull rope, battery draining because fan would always run key on or not, display showed overheating even on cold engine,. I thought temp sensor but with no return on electrical parts did not install. Local ATV repair guy thought stator as well but again because of electrical parts return policies did not change. Took to dealer, because of symptoms they immediately changed out the ECM and also discovered a bad battery.