Polaris - Module, Electronic, Control - 4010944

2003 Polaris Trail Boss 330 4x2. The ATV ran fine with the battery charged but it would not start the next time. It would usually start with the pull rope or if the battery was put on the charger. It had the battery replaced with the same results.

When I looked at it, I tested the battery voltage and it was under 8v. I started the ATV and tested voltage with it running, which should be 13-14.5v. There was no change.

I put a charger on it for a day (1.5a automatic) and attempted to start it. The battery was still at 6.5v and no lights came on on the dash. I found the fuseable link near the starter solenoid had burned in two. I replaced it with a 10a fuse which immediately blew.
I tested the wires to ground and found they were dead shorted (there are two red wires connected to the fuseable link) Both wires are bonded to each other at the control module so they will both test the same.

I removed the control module and tested from the pins the red wires went to to each of the others until I found the dead short. I consulted the manual and found the terminal connected to the brown wire which is a ground wire. I did test the new module from the brown wire pin to the red pins and did get measurable resistance however I do not remember what it was. Replaced the module and running voltage was fine.

The battery never took a charge so I removed it. It was very low on electrolite, which I topped off. It still would not charge over 8v and it ruined my 1.5a charger.

I believe (can't prove) the battery to have been defective (internal short), burning up the control module which was trying to put out max charging current constantly (which would boil the electrolyte out). I know it killed my charger. The battery was an Ever Start (Wal-mart)and was just out of warranty. A new Interstate to go along with the new module and good to go.