My '04 sportsman 600 instrument cluster went out the other day and the 4X4 stopped working simultaneously. Now the cluster will light up / 4X4 will work for a few seconds and then be gone for some time, then back again.

Looked for obvious loose connections, damage wires, etc., but no luck.

I read on another thread that low voltage may be a problem, so I charged the battery over night. Still no change with the problem.

Anyone have similar issues or any thoughts on what to look for?

I've checked the local auto parts places and haven't found a manual yet, so I'm plodding along in the dark without a schematic or wiring diagram. This only happens when it's cold and there's snow to be plowed.

 

i picked up a parts manual like the ones the techs use for 50 bucks
the place i got my bike got one for me has all the info i could ever want to know about my
bike in it

 

Thanks for the info. I finally found a Haynes manual, and though not as good as a factory book, it had a decent wiring diagram. It ended up leading me to a break in a ground wire associated with the grounding daisy chain for the instrument pod, hi beam light, etc. All is good again and I'm back to plowing snow.