Its a 2000 model and It keeps popping the 30a main fuse, well I thought maybe it was the winch so I disconnected all the wires going to it and it still does it. It had the rectifier so hot that it left burn marks on my hand when i touched it. You can also feel a wire inside the harness getting extemely hot (I cant tell which one because it is wraped up and I wanted some opinions before i cut the tape off). I thought it was a direct short somewhere but with the rectifier getting that hot it makes me think that there is something else causeing it. Any Ideas????

 

Try disconnecting winch wires from the source (battery, winch swicth) instead of from the winch itself. Maybe the bad connection is well before the winch. Also do you have any add on lights? I would also do a visual check on all the wires especially in the steering column (neck) and make sure there are no wires that wore down and could now be rubbing copper (+) against the frame (-).

Don

 

Thats where i disconnected it from was on the battery and I disconnected the switch wire as well. I am going to start looking under the steering stem next like you said for possible damage. Thanks

 

THE VOLTAGE REGULATORS GET REALLY HOT ON THE RANCHERS BY DESIGN. DONT KNOW WHY,BUY THEY ARE MADE THAT WAY..IF YOUR BATTERY IS FULLY CHARGED YOU CAN UNPLUG THE REGULATOR AND RIDE FOR HOURS TO SEE IF IT IS THE CULPRIT BEFORE THE BATTERY GOES DEAD. MAYBE THAT WOULD AT LEAST ELIMINATE THE CHARGING SYSTEM AS THE PROBLEM.

 

I put a new fuse in it and the rectifier will get really hot without the bike even running. So is there like a main turn on lead that could be the problem

 

I have a 2000 and had the exact same problem; poping the 30 amp fuse, running down the battery, and all. It turn out it was all in the rectifier. I replaced it and the problem was solved. I'm pretty sure it's you problem also.

 

Thanks for the replys I was thinking that it was in the rectifier as well, I just needed to hear someone else say it before I spent the $$$ on it