Need some help. Got more than a foot of snow and went to plow last night and my Polaris 300 sportsman worked for about 30 mins before all power was lost. I found the fuse unit and repaced a 15 amp that went bad. Worked again for about 2 mins then shut down, same as before. Fuse was blown again. Tried to replace only to blow as soon as I turned on the ignition. What to do now???? Any suggestions other than to take back to the dealer. Seems the dealer has had it many more hours than I have. Thanks for any helpfull replies.

 

Welcome To The Forum,sounds like you might have have a hot wire pinched some where on your winch.look closely at and around your winch and switch and battery, +loose grounds can also blow fuses.NEVER put a higher rated fuse in place of the proper value fuse,just before that higher amperage fuse blows you will smoke,burn and-or set fire to your bike,and---0%---will be covered by the dealership!!!

 

I am having the same issue with my Sportsman 300 (08). After using AWD for awhile while plowing, the fuse blows. Does not seem to be tied to the winch at all. After replacing the fuse and starting it up in 2 wheel drive, it works fine until shifting into AWD; fuse blows immediately. I let it sit for a period and cool off, and it works fine again until heating up. I have tried troubleshooting by removing the connector from the differential when this happens and it still blows. Could there be something (module or some control) between the switch and the differential?

 

Hope this might help. It is from my 2007 Hawkeye service manual.

AWD Control System

The front differential is controlled by the speedometer, the AWD switch, and the RUN/OFF switch

Battery voltage is supplied to the AWD coil when the operator turns the key switch to RUN, moves the AWD switch to AWD and moves the RUN/OFF switch to RUN.

The AWD coil ground circuit is supplied by the instrument gauge. The speedometer will not allow the AWD to engage when the engine RPM is 3100 RPM or higher.

I know it dosen't say too much, but it might help in tracing the problem down.

Like I said I hope it might help. If more info is needed, let me know maybe I can dig it up.

 

I had a similar issue with the wifeys Hawkeye 300 earlier this fall, blowing fuses, ended up being the, (Gorilla) winch contactor! It would short out and kill the bike! Hope this helps...

 

jokout, thanks for your support. When you detected it was the contactor (Relay?) for the winch, was it blowing the fuses only when shifting into AWD? I'm trying to tie it to the electronics for that, but I will try disconnecting the relay for the winch. Was the winch still operating normal? Did you replace the contactor to correct the problem?
Thanks, Jrgeo.

 

Hey thanks to everone who responded to my original message. Have tried to follow all the wiring but no luck in finding the location of the short. I have called the dealer and will let all know eventually what the result of their evaluation is. I have two 300's one is a 2007 Hawkeye and the other a 2008 Sportsman. Both bought at the same time and serviced at the 40 hour mark and both went down simultaniously at around the 41 hour mark when both experienced the same problem. Bolt holding the clutch assembly came loose and the unit wouldn't move(and in one of the ATVs'popped a hole in the clutch assembly cover). Needless to say they didn't run and had to go back to the dealer wherein I was told that they were out of warrenty and would have to pay again!!!! Anyone have any similar experiences and if so any different options. Since this seems to be more than just a coincedence when both go down for the same reason withen 10 minutes of each other has anyone heard of a recall because of this condition. These ATV were never abused and actually both went down in my driveway not in the woods.
Anyway Merry Christmas to all and thanks for your help.

 

the 2 things that blows fuses is either a short(direct power grounded out) or an overload onthe circuit to go highr then the fuse allows.

 

Well, after taking mine to the dealer to troubleshoot this problem, it appears to be a short within the speedometer unit. It is a sealed unit and has to be replaced. Although until I get the 4x4 back, I wont be 100% sure that is the cause. I will post another reply once I find out for sure.

 

Finally picked up my four-wheeler from the dealer today. According to them, the "aftermarket winch" is causing the problem. The manufacturer of the winch has you connect the actuator portion of the circuit (From the plow switch) into the key switch of the four wheeler; so it only works when the key is on. According to the dealer this is causing the speedometer head to short out. Of course they found this AFTER they hooked up the new speedo head. SO after buying two of these (@ 170 ea.) we are back in business. I hooked the winch power (From the switch) directly to the battery; with a fuse of course!