SurePower ECM Bypass Harness Kit for Polaris Sportsman, Magnum & Trail Boss 2003-2006
SurePower ECM Bypass Harness Kit for Polaris Sportsman, Magnum & Trail Boss 2003-2006
SKU:RMS900-107786
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SurePower ECM Bypass Harness Kit
Polaris Sportsman, Magnum & Trail Boss 330-700 - 2003-2006
Many years of Polaris ATVs used the SurePower ECM module, which controlled a great deal on the vehicle - circuit breakers, cooling fan operation and, most importantly, voltage regulation for the battery charging system. Most of those functions are reliable. The exception is the one that matters most: the voltage regulator rectifier inside the module often fails, and that normally leaves you replacing the entire module for the sake of a single function which is likely to fail again.
RMSTATOR built this SurePower module regulator bypass kit to put an end to that. The kit pairs a heavy duty CNC aluminium MOSFET voltage regulator rectifier with a plug and play wiring harness and mounting hardware. Mount the new regulator on the frame, plug in and route the harness directly to the stator connector and the battery terminals, and the machine is ready to ride. The kit is intended to bypass the internal voltage regulator on Polaris ATVs that use the older black box and the newer silver box SurePower ECM module with a single large connector. Part number RMS900-107786.
Key Features
- Bypasses the failure-prone voltage regulator inside the Polaris SurePower ECM module, so the module itself does not have to be replaced
- Heavy duty CNC machined aluminium MOSFET voltage regulator rectifier
- Plug and play wiring harness with 1000 mm wires and mounting hardware included
- The opposite connector for the main harness side is included as well
- Rated to a maximum charging current of 50 A / 500 W
- Suits both the older black box and the newer silver box SurePower module with a single large connector
- Operates from -20 C to 85 C
Technical Specs
| Specification | Detail |
|---|---|
| Regulator width | 103 mm |
| Regulator length | 103 mm |
| Regulator height | 28 mm |
| Fixation holes, centre to centre | 80 mm |
| Number of plugs (regulator) | 2 |
| Number of pins (regulator) | 5 |
| Number of wires (regulator) | 0 |
| Minimum charging voltage | 14.5 V +/- 0.5 V |
| Maximum charging current | 50 A / 500 W |
| Open circuit voltage | Less than 15 V |
| Operating temperature | -20 C to 85 C |
| Harness wire length | 1000 mm |
| Harness yellow wires | 3 |
| Harness red wires | 1 |
| Harness black wires | 1 |
| Harness plugs | 3 |
Vehicle Fitment Guide
Years shown are the overall coverage span for this part. Please confirm against the OEM part number on your original unit before ordering.
| Make & Model | Years |
|---|---|
| Polaris Sportsman 330-700 | 2003-2006 |
| Polaris Magnum 330-700 | 2003-2006 |
| Polaris Trail Boss 330-700 | 2003-2006 |
OEM Part Number Cross Reference
Aftermarket replacement. OEM part numbers are listed for reference only.
| Part Number | Manufacturer / Brand |
|---|---|
| 4010684 | Polaris |
| 4011088 | Polaris |
| 4010937 | Polaris |
| 4011110 | Polaris |
| 2203348 | Polaris |
| 2203349 | Polaris |
| 4010697 | Polaris |
| 4010944 | Polaris |
| 4011085 | Polaris |
| 2203130 | Polaris |
Frequently Asked Questions
Does the kit fit without modifying the machine?
Yes. The harness is plug and play. The regulator mounts to the frame using the supplied hardware, and the harness routes directly to the stator connector and the battery terminals. The fixation holes are 80 mm apart, centre to centre, so check that you have a flat area of frame large enough for the 103 mm by 103 mm regulator body.
What is included?
A heavy duty CNC aluminium MOSFET voltage regulator rectifier, a plug and play wiring harness with 1000 mm wires, mounting hardware, and the opposite connector for the main harness side.
How do I know the regulator inside my SurePower module has failed?
The usual signs are a battery that will not hold charge, charging voltage that stays below the normal 14.5 V at the battery terminals while the engine is running, or a battery that boils and overcharges. If the rest of the SurePower module still works but the charging system does not, the internal regulator is the likely cause and this bypass kit addresses it directly.
Does my SurePower module have to be the black box or the silver box?
Either. This kit is designed for Polaris ATVs using the older black box SurePower module and the newer silver box version with a single large connector. It is not intended for any other module type.
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