My 650 V2 is now waiting for it's 3rd ignition switch replacement in a year.

I can't figure out what's up with this thing, I found 4 broken/bared wires under the dash after it burned out the 2nd switch. Fixed them and thought that I had it cured, then last Friday I went to start it, turned on the key and all the dash lights came on for a second then went out. Battery it fully charged and load tested well, can jump the starter solenoid and it will crank for days but no start or power to anything. checked fuses for the 100th time and all are good.

Any ideas as to why this thing has now decided to start burning out switches?
I just want to get it fixed so I can unload this thing, a problem child from the start.

 

Do you have any add on accessories that are running with the switch? They could be over loading the switch if you are using the switch as main power for them. Or you have a bad wire/connection someware in the system

 

Is replacement switch an OEM or china junk switch?

 

All 3 are OEM. The first replacement lasted a month, the second maybe 5 months with very little usage, the third one is a used one and hasn't been installed yet.

I think I will put it in and trade it in on a different make.

 

Do you have any electrical added ons

 

Factory winch and aftermarket grip warmers, which are hooked into the winch power supply. Not were being used when the ignitions went bad.

 

winch hooked direct to battery? never hear of anyone hooking their heated grips to a winch power supply. usually their is a spot close to the bars on most machines that you can tap into for heated grips

 

The winch draws power directly from battery, the power for the solenoid is supplied through the ignition, ie. the key needs to be on for the winch to work. I tapped into that wire for the grips so when key is off grips are off, that way I don't need to remember to shut them off so they won't drain the battery.

 

really no reason to have the winch on a keyed source. mine does not even have a option for that. Winch could be pulling to much power through the ignition

 

I agree with Zrock...winch and grips need seperate power source if both in same circuit then this maybe an over heat problem to switch.