Went out Friday night my baby broke.

Lost all battery power. Replaced battery with new (thinking the battery just shorted out cause it was orginal) but it drains very quickly and goes dead again.

Have foglamps, winch and recently installed hand warmers (may be related, but no problems until warmers installed). With all disconnted, still have same problem.

Tested battery voltage at battery. Too low 11.6v.

Tested at alternator lead (as per manual) and have 60+v.

When she was acting up, even when key was turned back, the instrument panel stayed illuminated and headlights stayed on, but would not start until key turned ahead. Diconnected ignition switch, not change. Wiggled and checked a bunch of connectors and seemed when I played with the headlight/kill switch problem went away, but now I cannot duplicate problem. That problem went away, but charging problem still exists.

Not sure if related, but my temperature light has been flashing lately and fan did not seem to be working. Light flashing and overheating happened again while testing, but then I shut it off, was wiggling wiring harnesses & connecotrs, heard fan start up (ignition off) and now appears to be working (relay appears to have been shorted and have one on order, but fan is now working).

Any suggestions?

 

Have you checked the rear buss connector for corrosion/shorting?

 

At the regulator is ok, taking the rear fender off as we speak to check the wiring.

 

Click here for problem area!!

You nailed it!!

Thanks!!

Everyone who has one of these machines should preform this repair before it happens!!

 

Link to pictures of bad wiring