Ask the Editors: Tell Me About Fusible Links
What is it and where do I find it?
Most of us understand how a fuse works- too much voltage passes through a circuit and it blows to sever the connection before the spike can damage components further down the line.
The fusible link is similar but a bit different. They are simply strands of thin wire wrapped in a fireproof covering located between harnesses. They work like a fuse in that when a surge of voltage comes through, they actually melt before letting the components they connect to receive the damaging electrical load. Because they are wrapped in fireproof housing, the damage is isolated to the fine wires inside. The bad news of course is that when they’ve done their job for you, replacement is the only option.
In the case of the 2003 Polaris Sportsman 500 models, refer to the following diagram. It’s #27, located at the rear of the machine between the battery and taillight assembly:
It is OEM Manufacturer Part# 2202147.
