Anyone here ever burn up a handlebar switch? Polaris part #4010591. My 800 quit running while out in the woods. A friend of mine was riding it and I was on the wife's X2. To get it out of the woods, I had to hold slight sideways pressure on the red OFF/RUN/OFF switch to get it to run. I took the switch apart and something in there had shorted out. The back of the red switch had melted and then cooled, preventing the floating contacts on the back of the switch from contacting the switch board inside. I believe that it was localized to the switch, no other burnt wires, charring, or problems elsewhere. I had been thinking that I needed to go back though the thing and dielectric grease the crap out of everything could use it. I will before I ride it again after I get the new one. Water or anything else that comes into contact with housing can get into the switch. I was just wondering if anyone else had managed to burn one up. Thanks.

 

i would suppose there would be that much heat from 12 volts up on the handle bar. i wonder if something didnt start to short out?

 

That's what I was thinking. There was just a touch of dried up dieelctric grease inside the switch. I had been thinkng to repack all of the plugs anyway. I just didn't get to it before it caused me a problem.

 

If the switch was just at the point to make contact.......for a long period of time..........then this could of arc for some time before the switch did fail............
I had a similer problem in my older sidekick 4x4 with the turn signal switch lever..........It was just making contact and arc for awhile before I needed to clean it...........Do you use the key to shut your quad off??

If you do like me and many others the contacts on the kill switch never get moved so........one can only guess if the point of contact was good to start with...........Whooooooooo Please tell me that makes some since to you!!...LOL...LOL....Caper........

 

Caper, that did cross my mind. I have been using the switch more on Mama's X2 after I saw what happened to mine. Food for thought. Thanks.