friend has a 2002 sportsman 500 ho and riding it the other day it shorted out. To activate the winch there is a toggle switch by the speedometer (dealer installed) and it was on and he does not think it should of been.The lights went out and every switch quit working and when he shut it off it would not start again. any ideas? im stumped

 

can it be pull-started?

if it does start via pull start, does the dash or any light come on?

If not, a relay may have been tripped-- lemme know, but def turn off the winch switch (or disconnect it all together to check the rest of the system)

 

the quad is completely dead, no lights or anything. he has replaced all 3 of those fuses, is there a diff. between those and a relay? if so wheres the relays located?

 

if it can't be pull started, we might have a more serious issue going on-- i assume it cannot be pull started ?

the relays-- if i remember right, there is one under the front "hoood" and one in the back near the starter solenoid. Both are sealed in a black plastic "boot."

Check the battery voltage also-- if a cell collapsed in it, then that will give the same symptoms. If the voltage is <9v, try charging or replace it first.

 

yea if we are talking about the same thing, the black "boot", thats those plastic bag type things right? he found 3 of them and replaced them all

 

hmm... yeah those relays are what stopped all my electrical components on my 02--- My next step would be to check the keyswitch-- use a multimeter or test light and trace the power from the solenoid, into the switch, and out of the switch. It is possible the switch is not transmitting a signal that indicates teh "on" position.

Just as a random comment: -- did u check the "kill" switch on the left thumb control? I've drove myself nuts trying to start a machine when i accidentally switched it to off.

i hope something here helps-- i'm still thinking on it tho.