I am getting a low voltage shock to my thumb while riding . It is coming out of the thumb throttle, AWD/2WD housing, or maybe up through the handlebar? Has anyone ever experienced this? I think I might need to trace all wiring and see if there is a short or poor ground.

 

i wouldnt think it would be coming from the awd box as most of its plastic. start by unhooking the awd wire plug to see if elimnates that part and start working backwards. take apart the pod to see if some of the wires that come up around the steering post rubbed on the steel somewhere.

 

check your coil mounting bolts, or the plug wires for possible frame arc.

My bike was zapping me through the winch mount, that fixed it.

 

Are your rubber handlebar grips worn?............You can check your frame with a meter..........
Take your Pos(+) wire off your battery.............Then with your meter set to OHMS or continuity...Put one lead on the POS wire the other to a good "CLEAN" or "BARE" ground(bare not painted)......And if you get a reading there is a dead short to ground on your 12 volt(HOT) wire!!!.........Caper.........

Good luck........

 

I had a 99 XC500 sled and right from day one it would shock me even thru leather winter gloves. I only had it for a season as I bent the crank but it sure did keep my thumb warm LOL My 95 XLT before that and the 00 XC700 after that I never had a problem. Both my Scrambler and the SP have been good too.

Do you have hand and thumb warmers on it??

 

No, the grips are fine with no warmers or anything. The faster I go the more intense the voltage, I feel that it is coming up from the handle bar in tha gap between the grip and the throttle housing, I will check all the things you guys mentioned and see what I can find. It runs fine and the lights don't flicker or anything?