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Electrical problem on 06 sportsman 800

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Old Aug 23, 2013 | 04:01 AM
  #11  
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Thank you very much. Ill report back this evening to let you know what I figure out.
 
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Old Aug 23, 2013 | 06:42 PM
  #12  
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so i've checked under the fuse block, all connections are secure, no burnt wires that i can see. fuses are all good. there is continuity from the fuse block to everything in the pod. and everything in the light switch. i dont see any burnt wires or loose connections anywhere. i couldn't figure out how to get the "light switch housing" off to take it apart to check inside and see if anything is obviously wrong inside. so now i'm stumped.
 
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Old Aug 23, 2013 | 06:48 PM
  #13  
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There's a small allen screw at the back of the switch that locks it to the bar. You have to slide the grip off. An air gun makes easy work of removing the grip. Slide the switch off and take it apart on a bench as parts can go every where if you're not careful. If you heard the "sizzling" noise at this switch when you were wiring the lights,then you may have tracked the problem down. If you need a new one Cycle Parts Warehouse is fairly cheap compared to the dealers.
 
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Old Aug 24, 2013 | 09:39 PM
  #14  
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so i fixed the problem...at least temporarily. thank you for all of your help. the tip about the airgun really did make easy work of the handle bar grip. although it was all for naught because after taking the switch apart, on a work table as suggested, though still having a spring fly off, nothing was actually wrong with the switch.

After tracing every wire and looking at schematics, etc etc, i just so happened to have the key in the ignition in the on position when i was about to unhook the head light wire harness from the switch, as i wiggled it around trying to get it out...everything suddenly began to work... all i could see was that the pin for the green wire seemed slightly rusted or dirty (maybe burnt?) so i cleaned the pins on the wire harness and switch, hooked it back up and she runs perfectly now....i have no idea why that would cause everything on the bike to not work though....or maybe it didnt? i have no clue... very weird. i'm just glad it works again

And again, thank you so much for all of your help. is there any way i can leave you some positive feedback or something?
 
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Old Aug 25, 2013 | 01:11 AM
  #15  
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Ask any mechanic what he hates to work on the worst.. Electrical problems. Glad you got it running.
 
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