Check your circuit breakers you should have 2 of them and they are in sealed black pouches.

 

I have been looking for the circuit breakers you mentioned and I cannot find them. Could someone give me a hint as to where I should be looking. Keep in mind that my quad has a lot of "aftermarket wiring aka home depot style" that has been done. Are the circuit breakers you mentioned the type that will reset after a minute. If so, this could easily explain the power shutting off and coming back on as it seems to happen more after dark when the headlights are on for extended amounts of time.

As for the overheating problem, do Polaris quads have a thermostat like a car does. Could that be sticking closed and not allowing water to flow through? I did run the water hose through and water seemed to flow unimpeded both ways.

Thanks,

 

I got to thinking about this and I am now thinking the thermostat is either stuck open or missing altogether. I will check when I get home. I called my dealer and they said the price for a replacement is $70. Is there an alternative or aftermarket that would be cheaper?

 

Check Motorcycle Parts, Motorcycle Accessories ? BikeBandit.com for parts and diagrams. Get thermostat part # and see if it crosses with Napa, Autozone part #'s. I pull radiator and have radiator shop clean it out.

 

I pulled the thermostat housing off and sure enough the thermostat was completely missing. I went to o'reilly and autozone and neither one of them could match it up with anything. They even let me dig through all the stock myself. I have also spent several hours looking with 0 results. I guess I will have to bite the bullet and spend the $65 for a thermostat at the stealership. Online prices are even more due to shipping cost. I will pick one up or order it tomorrow and see how it goes.

 

Sorry to hear that. Keep in mind the previous owner may have pulled the thermostat because the radiator is stopped up. You may need to have it cleaned out, like I said.

 

I got the thermostat in yesterday and installed it, but the overheating problem continued. I dug a little further and I think I may have found the problem. The water pump impeller is installed backwards. The weird thing is I have never really had any overheating issues in the past. They just showed up recently in the last few months. I have not had a chance to bleed it all out and test it yet, but I am hopeful that will solve the problem.

 

Now that the thermostat is in and the impeller is corrected, the overheating problem is resolved for the most part. The electric is still cutting out, but I know why it is cutting out at least. The voltage is dropping down to around 5 volts when I am running me headlights and the fan comes on. It drops over a period of about 20 minutes when running. That causes the main solenoid to disengage and shut down everything except the engine.

The battery is brand new so I am thinking rectifier or magneto. I have an extra rectifier already, so I think I will start with that unless someone has a better idea what could be causing the voltage drop.

 

I think I finally have all the problems fixed. When I went out to change the rectifier, I noticed the battery was only at 11.5 volts even though it had been charging for over 24 hours. I washed off several layers of mud and noticed that one of the cells was a tiny bit low on fluid. After checking for cracks, I topped it off with some acid and everything started working like it is supposed to. The power no longer cuts off, the fan works properly, it runs cool now.

Now, onto my next project....