04 Freedom Touring electrical fail

Greetings from new member-

Interested in any input from more knowledgeable members as I try to choose between getting my old sled functional vs “regifting” it.

2004 Freedom Touring (model S04NT7DS). I got the sled for $500 4 seasons ago. I use it almost exclusively for ice fishing on Moosehead Lake in Maine. I have already got more than my money’s worth out of this machine. If I can keep it going for reasonable cost/effort I will. If not, I’ll give it to a buddy with way more time and mechanical skill than me and let him mess with it.

Seems pretty clear it’s an electrical issue. Symptoms are: At start of season I fully charged battery. After charge started right up and ran well. Early season was shit, so it sat for days/weeks before use. Battery needed recharging to start. Ran fine for short trips (back and forth to ice shack), but still needed recharge after sitting for days.

Yesterday went for a longer ride with a buddy. Probably the longest trip this sled had taken in 4 years. Ran fine. About 90 minutes in the check engine light started to flicker dimly, the engine sputtered a few time, then dead. When I got it home, started with a jump pack. Charged battery overnight, fires right up this morning.

Quick disclaimer- I’m mechanically ignorant, but I can follow directions pretty well. I have basic tools, but nothing to diagnose electrical issues (ie- measure voltage,test continuity, etc). Last night I went down the internet rabbit hole of threads on similar topics.

My guesses:

1- battery is part of the problem (should hold charge longer between use), but shouldn’t be the whole problem. Otherwise shouldn’t it function while the engine is running?

2- bad Voltage Regulator/Rectifier? I can see that the original was already replaced with an aftermarket unit (the original is part 4010538, the replacement is 4011100). No idea how long ago. From what I’ve read, cheap aftermarket units can be unreliable. The new one was mounted in a very accessible spot (the original was just left in place. The old connections are just hanging there). Would failure of this part be consistent with my issues? Replacing this would be cheap and easy.

3- Do these symptoms fit better with a different electrical failure? ACS? Coil? Stator? Something else I haven’t heard of?

Thanks for any suggestions. Like I said, I’m not going to chase this too hard. Next weekend my more mechanical friends will be around to help troubleshoot.…… JB

So I don't know much about those early 4S models but I do know they had a much different electrical system than the 2-stroke sleds of that era. Hard to say for sure without an electrical diagram but I'm guessing the stator output is split into different independent circuits, one to run the sled (engine ecu) & charging, one for the spark coils, and one for lights and accessories.
Looking at the parts diagrams for that system, it looks like there was a alternator control switch (#7 in the link below), that would be my guess is what failed. Unfortunately it's not available anymore, as are most parts for that sled, but you could try the dismantlers like Al's in VT or Hudons to see if they have one.
Could very well be the aftermarket VR since they are known to be crap but usually the lights and the handwarmers are affected when that one goes. Not sure I'd want to risk throwing a OEM one at it considering they are $214 list price.
All that being said, I think your initial thoughts of letting it move on are probably the best move. Those were the first generation 4S models for polaris and the parts are becoming extinct at this point.
You could probably nurse it thru the rest of the season by charging the battery before using it if all you are doing is heading to the ice shack on the lake, you'll likely get a much better price on something different waiting for the end of the season or summer.
Start looking around for a Voyager or Indy with the 550 fan 2 stroke, sounds like that would work better for what you do. Much less complicated with only carburetors. I'd avoid the 550 fan in the edge style sled you currently have, something with that hood design had poor cooling and they were known to cook the motor.
How the ice on the lake? Guessing the crossing at Kineo is still not open yet?

850Switchback said:

So I don't know much about those early 4S models but I do know they had a much different electrical system than the 2-stroke sleds of that era. Hard to say for sure without an electrical diagram but I'm guessing the stator output is split into different independent circuits, one to run the sled (engine ecu) & charging, one for the spark coils, and one for lights and accessories.
Looking at the parts diagrams for that system, it looks like there was a alternator control switch (#7 in the link below), that would be my guess is what failed. Unfortunately it's not available anymore, as are most parts for that sled, but you could try the dismantlers like Al's in VT or Hudons to see if they have one.
Could very well be the aftermarket VR since they are known to be crap but usually the lights and the handwarmers are affected when that one goes. Not sure I'd want to risk throwing a OEM one at it considering they are $214 list price.
All that being said, I think your initial thoughts of letting it move on are probably the best move. Those were the first generation 4S models for polaris and the parts are becoming extinct at this point.
You could probably nurse it thru the rest of the season by charging the battery before using it if all you are doing is heading to the ice shack on the lake, you'll likely get a much better price on something different waiting for the end of the season or summer.
Start looking around for a Voyager or Indy with the 550 fan 2 stroke, sounds like that would work better for what you do. Much less complicated with only carburetors. I'd avoid the 550 fan in the edge style sled you currently have, something with that hood design had poor cooling and they were known to cook the motor.
How the ice on the lake? Guessing the crossing at Kineo is still not open yet?

https://www.polaris.com/en-us/snowmobiles/assembly/?modelId=S04NT7DS&assemblyId=184688

Click to expand...

Thanks for the helpful reply.
I’ll probably just try the new $60 aftermarket VR, a different battery, and stick with short trips to the shed.

Winter has been slow to arrive at Moosehead. The coves are frozen, but I’m still avoiding the open lake. Decent cover on the open trails, but anything under tree cover still sketchy. At least the fishing in the cove has been good!

Happy trails…. JB

Positive results so far.
Installed new AGM battery. Replaced old aftermarket Voltage Regulator/rectifier with new aftermarket. (Btw- you get what you pay for. Had to file plastic debris out of connectors to get them to seat properly.)
Sled starts and runs well. Tach and hand-warmers, which had been inactive, now work.
Also bought a cheap multimeter. Battery measures 12.2V with engine off, 13.5V at idle. Hopefully this means it will charge adequately.
Next time I run it I’ll bring the meter with me so I can see if I’m draining the battery.
JB

That is a good start, a fully charged battery is 12.7 volts so anything above that means the system is charging.
Don't be surprised if it cuts out charging at low idle when you meter it. They usually cut off charging & non-essential loads until the stator gets more RPM.
Be interesting to see how long it lasts, as you probably already read in other posts those aftermarket units seem to last anywhere from 30 seconds to 3 years. But at least you know where to start if it does this again.