I joined this forum just now to inform a problem that I couldn't find on any of the forum sites. Purchased a 2001 xplorer 250 from a private seller. Everything seemed fine at the time of purchase. Brought it home, rode it for a half hour, and then all electric went dead. It still ran fine, stating with pull rope. A big red flag was when I found a wiring diagram tucked into the owners manual. But it was a diagram for a 2001 trailblazer. Which doesn't have 4wd, a high beam, or cooling fan. Had it been specifically for my machine I may have figured this out much sooner. The circuit breaker was tripping. Noticed wires to LH switch was getting warm, so I took the switch apart and cleaned it. Seemed fine to begin with. All power runs through the key, then the LH switches. Problem returns. Wasn't charging, so I bought a new voltage regulator off Amazon, I got charging, not tripping fixed! for a little while, problem returns. Unplugged every thing in the harness, N and R switches, fan, lights stator, etc. Still tripping breaker. Thought the LH switch maybe had a problem bought a new one off Amazon. Still tripping. Took the whole machine apart, pull ALL the wires out of the loom, found nothing obvious. What I missed was the temp sensor switch for the fan which is hiding under the frame, behind the head, near the carburetor. Was the one thing I didn't unplug when I began this project. Unplugged it and the breaker stopped tripping. So I put it all back together, still not charging. Put the original regulator back on, charging again. Now that LH switch I bought off Amazon failed too. The off run off switch stuck, and then broke. They are identical inside, but maybe a fluke failure. Either way, I purchased two non oem electrical parts, that I didn't need anyway, that failed. Now, all along, when I put it in reverse, the engine would kill, unless I held the override button. I thought it had something to do with the tripping breaker problem, but not. Seems to be a bad rev box. I found on a forum to pull the black wire from it and yes, it stopping killing. Seems to be a common polaris problem. I figured if I could help anyone out with this, it would make up for the loss of a weeks worth of nights, a hundred dollars of unnecessary parts, and possibly a marriage, haha.
Anyone know how to make the rear brake work better?