I have a 1989 250 Trailboss 4X4. When in 4x4 the circuit breaker goes on & off. I worked on it the other day and with the front coils unplugged it still did it. It also seems to do it more often when riding than when stopped. The connector for the micro switches on the shift lever got real hot, also I have checked the connections at all of the connectors I could find. Could it be the switch on the gear case? Can it be removed with out removing case from 4 wheeler? I have a Clymer manual but I couldn't find anything about the problem I am having.

 

It almost sounds like you have a wire rubbed through somewhere. That would explain tripping the breaker with the coils unplugged, and the fact that it seems worse when riding than when sitting still. I too have the Clymer's manual, and it is good about how to take apart and put it together, but is poor at troubleshooting.

Do you have a circuit tester? I would suggest with the coils unplugged to see how much resistance there is in the leads going to them. My guess is there is close to a dead short somewhere......as to where...????????

 

There is very little resistance in the leads going to the coils, one of the coils is only a couple of weeks old and the readings on both are almost identical. I guess I will have to keep trying to follow the wires through all the places you cant see into.

Thanks!