i have a 98 sportsman. the lights started dying out and then coming back on after a minute or so.at the same time i would here the inline breaker of sorts clicking on and off from under the seat and wires in the harness would get realy hot. dealer said i had melted wires in my light switch causing a back feed.
they replaced the switch and after 10 minutes of riding it died completly and overheated
after it cooled it started up
now the dealer says the fan motor has a dead spot causing the wires to get hot and machine to overheat
i think they are finding symptoms of a promblem,not the problem.
any ideas?

 

it sounds like you may have a dead shrt somewhere. a posative wire grounding out on the frame somewhere. check the voltage to see what it is when its running if you can. trace some wires from battery on to look for rubbing, or fryed wires hitting some metal.