How to Test Circuit Breakers on a Polaris Sportsman ATV - Electrical Issue DIY

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This video provides a quick DIY tutorial on how to test the circuit breakers on a 2003 Polaris Sportsman 500. I was trying to diagnose the electrical issue I was having with my Sportsman four-wheeler. It seemed like I had no power to my speedometer as there was nothing on the display. The electric start and 4wd drive did not work either. I did have lights, but no power to the pod. The issue ended up being one of the electrical connectors going to the left handlebar assembly. The circuit breakers on this four-wheeler are used instead of fuses. It is common for moisture to corrode the circuit breakers and cause similar electrical problems on these Polaris ATVs. I've seen quite a few people in the forums asking where these circuit breaker bags are located as well as how to test them.
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Due to factors beyond the control of Mark Jenkins, I cannot guarantee against improper use or unauthorized modifications of this information. Mark Jenkins assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. Use this information at your own risk. Mark Jenkins recommends safe practices when working on vehicles and or with tools seen or implied in this video. Due to factors beyond the control of Mark Jenkins, no information contained in this video shall create any expressed or implied warranty or guarantee of any particular result. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not Mark Jenkins.

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11 сен 2024

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Комментарии : 87

@nogripes 2 года назад

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@stuartbeasley7879 2 года назад

Thanks for your videos on The Sportsman. I bought a 2000 400 Sportsman yesterday to restore.

@BruteEngine 11 лет назад

I was having the same EXACT issue on my '99 Sportsman... This video saved me from pulling my hair out. Thank you so much for posting this!!!!

@JCsBees 7 лет назад

You were right, I just had to push in the plug to the kill switch. Thanks a million for sharing this video.

@MichaelStiemsma 11 лет назад

WOW Thank you so so so much . sat there for about 3 hours trying to find the exact same problem! thank you so much for sharing this. i cleaned both plugs and on the male end i took a flat head screwdriver and very slightly bent the prongs inside so they would get a better connection. Again thanks for help.

@polaris_extremis Год назад

Thank you so much. I checked them and found a rusty one. That should be the fix!!!

@themodernheretic 10 лет назад

Thanks Mark,..... I had the same problem with My 2000 Polaris 250.....I checked the connection you mentioned... and the console lights came right on....Saved me a trip to the Shop..... Thanks again... Geo. Perry Jett, (SouthWest Arkansas)

@Twoholesofman 2 года назад

Thanks for taking the time to make an intelligible and helpful video.

@waydepahl1913 10 лет назад

Thanks for showing me your problem. I had no power for my lights or anything. But the motor would run.On my 2003 sportsman My breakers looked great but the switch control on the left handle bar was louse and caused me to lose power. I adjusted it and the power came back and I tighten them, And it work good now thanks. Wayde

@jedmiller1713 7 лет назад

THANK YOU!! After a week of frustration this was my exact problem

@adamblanchardprogamer0464 8 лет назад

would like to thank you for posting this video, made me check my connections on left switch and found my problem. thank you so much.

@EnormousNumber 4 года назад

bro, i was excited to see someone had a youtube video for my exact problem. Imagine how stoked I was when I saw you are in Maine! Im in from Maine too! haha great video bro

@foobaarr 5 лет назад

thank you for taking the time to post very helpfull

@donaldberry8040 7 лет назад

Hey guys.. Mine had the same problem and it was entirely from a dirty on/off kill switch. Remove the left hand grip and the 3 small screws and slide the case back about half an inch and spray in some WD40 or contact cleaner. Reassemble it and work the switch side to side several times. It worked fine on mine even kept the lights from coming on. I'm almost bald now from too much stress but this worked for mine.. whew

@Kev_Stuntz Год назад

Thank you for the help

@keithcampbell7820 3 года назад

So the best way to troubleshoot the breakers is to use a sharp probe to the wire on the load side of the connector. The small hole left can be sealed with a dab of rtv. If you do have to open the bag, lightly fill with silicone grease before taping. Yea it’s messy but effective.

@delmontindustriesltd7501 8 лет назад

Thanks for posting this. I need to dig into the electrical on my 02 Sportsman. The lights, AWD, Winch (switch) randomly go on and off While it's running. I'm thinking its' corrosion and dirt on the connections. But at least your video kind of gives me a direction. Thanks again for posting. -Nick.

@delmontindustriesltd7501 8 лет назад

+Mark Jenkins I will give that a try. Thanks!

@Troy77787 Год назад

If I’m getting a clicking sound at my starter solenoid, would I possibly still need to replace both of the pods at the front of the machine? thanks

@vadimsdembovskis8819 2 года назад

hi i have a polaris sportsman 500 h.o 2003 carburetor no 100 volts on the blue white wire that comes out with the cdi unit what could be the problem

@robertleto6692 9 месяцев назад

Did your instrument pod light up with your previous problem

@matc2013 11 лет назад

that video was more helpful than my polaris dealer thank is there any more fuses or anything like that ive got no power any where to anything

@doggmarcott5389 3 года назад

Either I have a 250 trailblazer and I can't get the light panel indicator light panel to hook up so I can get the neutral light so I can start it

@anonymoussubscriber3929 6 лет назад

Do you still have the brute force in the background?

@grahambinoo 9 лет назад

Thank so you !! Great post !!!

@MrTbdesigns 10 лет назад

One of the breakers is white like yours was in the video and I did check the connections, but the breakers is being a problem because I don't have anything I could test them with cause the volt meter thing I'm trying with is hard to understand and all I do is read zero.

@deedadon7142 2 года назад

What size is circuit box mines too corroded to tell

@citionriver 4 года назад

I have polaris 2001. When I turn ignition on I don't get any power and it would not start. But if I manually pull starting cord it turns on fine. I checked battery it was swelling. Checked voltage regulator and it gave the same power out as it was in. Replaced that. But still don't get any power with key on. Checked battery and get 12.5 V. Any thoughts how to test what can be broken? Thank you in advance

@fernandogodinho9656 8 лет назад

Thank you. I'll check that out.

@Camerons16 6 лет назад

I have the same exact atv and I’m having a problem where the atv starts and runs for about 1 minute and then dies.. power, headlights, everything.. If I wait about a minute it will start right back up and do it again. Any suggestions?

@dougkirkland2803 8 лет назад

I have a 2001 polaris 400 sportsman with an electrical problem the left handle bar switch with the red white wire has burnt at the plug. replaced it with a new switch and plug that I spliced the wires to. have low beams no high beam and the starter doesn,t work. bike starts with the pull start. the red white wire is not connected if I connect it it wants to burn. any help would be appreciated

@MichaelStiemsma 11 лет назад

BTW it was a 2003 500 4x4 scrambler that i had . same exact problem you had.

@truenorthmuskoka9077 Год назад

This is an old video so I hope someone replies. My polaris electrical shutdowns as soon as I either turn the lights on, or apply the hand break to illuminate the rear light. Also loose speedometer lights. After about 1 minute power is restored. If I try to turn on any lights it happens again. Could this be the circuit breaker. I read it could be overheating then once it cools power is restored.

@brianschermerhorn9479 10 лет назад

I have an 04 sportsman 700 efi.. I have the same problem .. no power to speedometer assembly no lites no power to key.. the book says I have cuircut breakers but I dont find the "bags" as in yours.. any sugestions?

@eagleflight7501 4 года назад

I'm having the same problem on my 2018 sportsman no speedo or anything on digital display any tips on what else to check

@petergardner8532 6 лет назад

Mark, I got an 04.5 Sportsman 500, the high beam didn't work so I traced it to one of the brown wires that somehow got pinched and was flattened so I soldered it back together only to find the other brown wire was the same way, so i soldered that one back together now the high beam works but now I noticed the speedo pod is completely dead, it worked fine before I stated working on the wiring, it starts, runs, kill switch works, high, low beams work, but everything in the speedo is dead now.I thought it might be a fuse somewhere but I guess these don't have fuses? so I replaced the ecm in it because theres suppose to be breakers in it? for $150 which didn't fix it. Could the new oem ecm be bad, thats a possibility or is there something or somewhere else to look? other breakers somewhere?

@tyemunro4056 5 лет назад

I have a 2001 Polaris sportsman 500 and I’m trying to find the fuse to my fan, can’t seem to find it, Is it possibly in that bag?

@charliegrant7188 10 лет назад

HI I have a 2006 330 and I have no head lights no dash display but my fan does kick on every time I turn on the key (that is normal). I do not see anything that looks like those circuit breakers on your video. do you have any suggestions?

@erikbenner7234 8 лет назад

Im having the same problem on my 2001 500 ho and anything that is connected to the handlebars or pod is not working and I have no head lights or speedometer or 4x4 all worked before my electric start stopped working. Could this be my problem if not what else do you think it could be? Thanks

@fernandogodinho9656 8 лет назад

Thanks I will try that.

@MrTbdesigns 10 лет назад

Hey I have a polaris predator 500 I cut the breakers out and I have the issue with no power comes on at all I want to know what did you set your tester on to see if the breakers were bad.

@g00glechr0me8 8 лет назад

My 2013 sportsman 400 wont start...its just clicks once and that's it..the battery is new, all the power/lights work....I think its the starter or the solenoid. How can I test to see what it is? How exactly do I jump the solenoid to test it? Thanks.

@YourFavoriteJdmMamii 10 лет назад

Hey im having a problem with my Polaris im tryna find the circuit breaker i cant find it or it doesn't have one can u help me please

@robertdecker7690 10 лет назад

I have a Polaris 2004.5 sportsman 400. I'll be riding along and my lights and speedometer will go out,and come back on and go out again. a little hazardous when running at night. any suggestions of what might be causing this.

@scottparish9079 9 лет назад

It appears that you used a different breaker. Probably cheaper, what did you use when you replaced it?

@Ducuka3E 5 лет назад

Hey Mark on my 500 Polaris sportsman whenever I grasp handbrake it shorts motor so I move run/ off switch on handlebar back and forth then check lights and she starts right up, would you have any idea why the handbrake could short run/off switch, Thx in advance - Donn

@suhhduhh8857 9 лет назад

Hi , I have a Polaris predator 500 & I was riding one day and my battery fell and I lost power and whenever I tried connecting the battery back , I had no more power , my light switch nothing would turn on... You think the breakers is what messed up ??

@ericknowles5169 6 лет назад

Hey man I have same wheeler and mine is shorting out positive side of battery. Really weird. But any suggestions ?

@steverichards2996 6 лет назад

just put new stator & regulator getting 13.3 volt but my fuel and speedometer flash what could cause this

@809FILMS 11 лет назад

what if your speedometer does not work got any thing to help me thanks

@alexmadden2858 3 года назад

What setting do you put the multimeter on?

@nbw_1383 5 лет назад

Some help me I have 850cc Polaris sports man 2016 and it got flooded and the water went into the motar and I tried to turn it on while it still had water in it and it made it worst some one plz help

@dougsowder7430 11 лет назад

Mark, Thanks for the videos...I have the same question as polaris sportsman, my speedo has power (shows miles, hours, etc) but the speedo doesnt register a speed. Any tips?

@SticksNkicks 4 года назад

My 06 450 has no headlights. Light swith is testing good. I dont believe the 06 has the circuit breakers. Taillights and rear work lights work.

@roytaylor6116 6 лет назад

Is it all breakers or Fuses

@fernandogodinho9656 8 лет назад

Great videos. Mark I need your help. I'm having a couple issues with my 2002 Polaris sportsman 400. Four wheel drive the front left Hilliard clutch doesn't seem to engage. I've replaced both seals, Hilliard clutch and all four bearings. I've checked the wiring and it seems ok. ?? Second, I'm starting to loose power, especially going up hills. I've replaced the belt drive, and carb. All original parts. Do you think it may be the clutch? Any tips will be appreciated. You got me started with all this.., lol thanks for sharing.

@johnnyboyrules12 8 лет назад

+Mark Jenkins what setting did u use to test ur power?

@mikeharmon8733 4 года назад

Those look like fuses. You call them circuit breakers and relays?

@samueltumblershop 10 лет назад

I have a 2003 polaris sportman 500ho the kill switch dont work and awd dont work

@tygerluv777 8 лет назад

Any idea about this? I just changed my voltage regulator because it wasn't charging my battery. Stator tested to be seemingly fine. But now, my Tach will idle at about 800, then when revved, will drop. I can lightly engage my brakes, and the tach reads fine. Did I buy a faulty regulator? There are some forums saying it could be a bad ground, but I can't find anything loose or dirty. Any help would be awesome!!

@tygerluv777 8 лет назад

+Mark Jenkins Thanks for the reply! So what would happen is only the tach read wrong. You could hear the RPMs raising, telling you the tach was reading wrong. I searched for bad grounds, and came up with nothing. I decided to plug the old voltage regulator in (to be sure that one read the tach correctly, even though it didn't charge the battery) and it read fine. So I was thinking I bought a faulty regulator. Plugged the new one back in and it worked fine! Not sure what happened there, but the battery charges and the tach reads fine now. Thanks for your input and I hope this can help someone else in the future.

@MrTbdesigns 10 лет назад

So you think if I change one of the breakers it should work? Cause it's the same as when you said your headlights and such didn't work and that's what's wrong with mine and I mean nothing turns on does start no absolutely no power.

@YourFavoriteJdmMamii 10 лет назад

I got the same problem plz help im going crazy lol

@MrTbdesigns 10 лет назад

Carmen Hernandez on my bike it was actually my switch cause i replaced all the wires i mean i had to because i burnt my wires up, but what was wrong with mine was the ignition switch.

@anonymoussubscriber3929 6 лет назад

Taylor Blanchard I am working on a 08 trail boss 330 that has no power to the handle bars, makes a clicking sound when I go to turn it over and head and tail lights work.

@tomgearhart7133 9 лет назад

hey mark i have no lights winch stop working 4wd stopped.engine starts up with pull ,start changed battery (which was dead ) to new. motor starts that's it. only found 1 bag for fuse its a 2001 is there a difference??????

@tomgearhart7133 9 лет назад

mark the winch works with new battery no lights or 4wd breaker was good only 1 bag

@albertjacobson3912 11 лет назад

I watched what you did to test the breakers. I have lights ,but they blink on and off while driving. What do I look for? I pulled the connectors loose from the light switch and reinstalled them(they did look good).

@austinhill2776 7 лет назад

My speedometer won't work on my 2002 Polaris sportsman 500 ho

@MrTbdesigns 10 лет назад

Alrighty man I'll try to get to that, of it ain't the breakers I don't know what it is.

@marcopenner108 9 лет назад

hey Mark, I am having problems with my speedometer. I am having power to my info screen but the analog speedo will not work. Any suggestions?

@marcopenner108 9 лет назад

***** it is a 2001 500 h.o. I will check it out thank you.

@dickiewycoff3918 6 лет назад

Marco Penner i have a 04 sportsman 500 i did a total frame change out with all my parts on the other frame now i have no power anywhere

@samueltumblershop 10 лет назад

Hey mark could u help me on how to fixs my awd to work and to help me get my kill switch to work again on tell me how to get them to work again

@samueltumblershop 10 лет назад

See if ur CDI box is bad wat wires under the hood do i test if its not my hubs

@jimmybrown2124 9 лет назад

Samuel Simons

@ahankins19 11 лет назад

Mine keeps sayin HOT Check engine but my spedo is working

@kakan482 6 лет назад

having the same problem with my 2015 sportsman 1000 xp

@tommyaustin556 9 лет назад

My 2010 Polaris runs but shuts off but won't start back until it cools off

@scottypetty9117 2 года назад

Probably the stator

@johnnewville6459 Год назад

@nogripes Год назад

$85!!!!

@yinzertv873 4 года назад

I have an 03 predator 500 and it has 2 of the same circuit breakers on it and the one near the back of the quad when turned off does this clicking every few seconds and drains my battery. Any thoughts or suggestions?

@matthewrobert2888 4 года назад

Hey I had a question for you soon as I turn my key the relay pops and I get 12 volts on my relay on both sides but soon as I turn the key it pops then one side of the relay has power and the other side doesn't have anything could this be a bad relay problem do you know by chance

@stephenburton9139 9 лет назад

i have trouble with my 500 6x6 sportsman 2007 the rad fan stay on and there is no power to anything else can , when i turn the key nothing happen, you help