500 Sportsman electrical problem

2000 500 Sportsman. 12volts on battery when ignition off, 4.5 - 5.0 volts on battery when ignition switched on and vehicle not running. Battery is being drained. Thought it was starter or starter relay, both seem to test fine on bench. Am able to apply 12v through both and starter spins freely? Any way to test them or any other thoughts of where to look for the problem?

EEK! Hmm... sounds like a short (yeah I know... "Duhh")

I'd look through the wiring (especially primary wires that carry 12V throughout the machine) for rub-through or cross-over.

Might even be caused by water invasion to plugs on the machine creating a short to the frame or grounding out.

Just a few shots in the dark.

I'd grab the wiring harness and shake it around... even (as crude as it may sound) pick the machine up and drop it a couple times (to shake the wiring around a bit and either shift the wiring that might be causing the problem away from the frame... or shake the moisture out of the connection.

Getting the machine GOOD and HOT (riding the crap out of it) will be your best bet.... if moisture is causing the problem (which is not at all rare) the heat from the motor will dry it out normally.

Good luck and let us know how it goes.

Ride Safe,

Chuck

Take off the front rack and check the yellow/red wire from the regulator (mounted in front of the rad) along the frame (riders left). The wire may have come disconnected as it is a bit short. There are several bullet connectors, make sure their pushed in all the way. had the same problem a month ago.

good luck,