First I'll start with the things that I did, then I'll start with the problems I am having.

2004 Sportsman 700 - I took the winch out and took the plow mount off. Was going to go riding today. It was running fine before the ride. As soon as the ride started, it would die. For the rest of the day the problems were: loss of power to the headlight pod; all lights would turn off; would let it sit for a few minutes with the key in the on position, lights would turn back on and then off again. Seems to be that if the lights were turned off and the key in the on position, it would take longer for it to lose power. A couple times when this happened, the fan would run if it was hot from idling, so I am thinking that the electrical is fine. Any thoughts or similar problems? Please help!

 

just a follow up on this one. I was under the headlight pod checking all the wires and came across a few wires in the plastic bubble protector. A couple of red and black wires that goto the key switch. This was getting a little warm and melting the bubble a bit. I cut it open and its all rusted but still together. Getting warm. Is this the circuit breaker? If so could that cause said problem when getting warm with the key on? Anybody have the electrical parts of a 2004 service manual with some tests and diagrams? Let me know any input

 

Yes that is a circuit breaker and it is a common problem, you can get a new one at the local auto parts stores for a few dollars, Get some dielectric grease also and coat the connections and case seams to seal it better from moisture.

 

ok thanks for the help everybody... I did replace the circuit breaker with one from the parts store and all seems to work good now. I had to mod the breaker with female connectors and electrical taped the thing to try to keep the moisture out. I hope this will help somebody in the future.