i have identical trouble , i will try cleaning grounds , will post back....hopefully one of us can find our trouble.......

 

<div class="FTQUOTE"><begin quote>Originally posted by: swothe

I just bought an 04 700 (non-EFI) and I have a problem when the lights are turned on. After running for a couple of minutes, everything shuts off and the engine dies. After about 30 seconds, everything comes back on, and I can start the engine. If I just turn on the key without starting the engine, the lights will come on, and the info panel will light up, but then shut off after a minute or so, and then come back on again after 30 seconds. If I turn the lights off - no problem. I put on 110 miles on Saturday with no trouble, except when I tried turning the lights on. It is not flashing any sort of warning prior to kicking out, and there is plenty of battery. One item of note, the guy who had it before me replaced the kill switch. Any ideas?
</end quote></div>

Not being a mechanic and only looking at the wiring diagram briefly, the headlight power comes through the key to the red slide switch and then to the headlight switch and then onto the headlights.

Could be an overcurrent somewhere: Bad headlight, bare wire in the headlight grounding out slightly, a mod added that is taking too much power and over heating the kill switch or tripping the circuit breaker.

Question for you. Do you have any headlight mods, such as extra plow lights or the three headlight mod? Does it do this with both the low beams and the high beams, or just one of them?

The more I'm looking at how power is flowing, the less I'm liking the way most of the three headlight mods work...it's just pulling too much power through the small wires [img]i/expressions/face-icon-small-frown.gif[/img] Anything trying to pull all three headlight's power through the little switches looks like it's simply melting them. Anyone else have this problem? Anyone with any extra headlight mods even ever touched their kill switch and know whether they have a problem or not?

 

I think that you are right dosceola. The wheeler only shuts off when the lights are on. I will look into rectifying the situation. The lights would dim about 20 sec before shut down. I will let everyone know what happens.

 

CHATTERBOX41.........My friend had the exact same thing wrong with his. THIS IS HOW WE FIXED IT.......There is a "pouch" that holds three(I think) fuses inside. This pouch is supposed to keep them dry. Water evenually finds its way inside and corrodes the connections. They are located just below or behind the headlight. He replaced all fuses and was good to go.

 

I just copied and pasted this quote from a fellow Polaris owner that steered us in the right direction.





"Sounds like the self resetting breaker is tripping. It is a 20 Amp breaker located inside a sealed plastic pouch. Water will get in there and create corrosion on the terminals and make the breaker trip. There could also be a wiring problem making the breaker trip, but I would start at looking at the breaker itself as it has been known to get corroded and rusted".

"If ever you think the breaker is no good, you can get one at an autoparts store. I bought one at Princess Auto for $4.49 and it is identical to the Polaris unit".

Check the link for online Parts manual...look under Electrical-Tail light for the 2004 Sportsman 600 "

http://parts.polarisind.com/Browse/Browse.asp

 

i am having the same problem with a 2005 Sportsman 500non efi. If I Turn the headlights on it will kill the engine running or not. Sometimes the lights will last 5min sometimes not at all....Pllz help.

 

also, this black pouch you guys talk about I can find it on my 335 but not on the 500, where is it on 05and up?

 

Sorry I don't know, my friends is a 2004 600 twin. It was just below headlight.

 

I cut open the first pouch and found a like-new 20A breaker inside. However, when I cut the second pouch away, I found another 20A breaker that was rotton as hell. I have changed out the parts and the wheeler seems to be running fine now. I will let everyone know if something else happens. Thanks to everyone that has posted on this.[img]i/expressions/face-icon-small-happy.gif[/img]

 

just to let you guys know......On my 2006 Sp 450.........I am on my third ECm "Black Box"

The first replacement was do to the quad shutting off as soon as the headlights were turn on!!........This was controled in the ECM,or PDM whayever you want too call it...........It was replaced and fixed the trouble,..............Circuit breakers inside the module!!.......

Now that replacement acted up last week on me,Different problem this time, Fan running with thw quad engine cold sitting there for several hours with out the key in!!........Fan ran until the battery was dead!!..............Replaced ECM again (both were covered,no cost to me)........Fixed the problem..........................

One thing I need to say here is .....the newer controls on these quads cover one he11 of alot of STUFF!!!!!!!!!!!!!!!!!!....TOO much in my view..........Why can't polaris install the relays separte,along with the circuit breakers and controls?

Here is what the Sure Power Box does:

1.Alternator rectifier/regulator
2.engine temperature controller
3.solid state circuit breaker outputs.


This is now my third one on a 2006 quad with about 1500 miles!!!!.......

Lets see how long this one will last!!''

BTW my wife's 450 still has the factory one in there!!!....Don't ask me why it still working!!!......................................Ca per..............