I have a 2005 Sportsman 400. The instrument cluster will backout on occasion and takes winch operation with it. I have a feeling the problem is with the ignition switch. I have checked and cleaned all connections and metered all connections for the winch, replace the relay, and the control switch. The problem seems to be worse when it is weather is cold. The power for the winch switch is connected to the ignition side for power at the manufacturer's suggested point under the headlight.

Any suggestions? email me racingrescue@sbcglobal.net

 

Welcome to the forum! There's a whole lot of fine wires in the speedo connector harness that could be causing the problem. This area is bad on shorts because of all the turning and twisting. You might try tracing this harness down a ways and see if you can find any bare or broken wires. Plus you can check the switch wiring also. OPT

 

welcome to the forum. as long as it's a hot wire when the key is on is good for the winch. i think the recommened wire was orange/white, or you could have gone off the access. out let on the pod for power. just a thought.

 

The winch switch is connected to the orange/white wire beneath the light pod. I heave traced the wiring harness as best possible for any problems. Just came in from garage and Have found that once the machine is started, if the cluster is out, turning it off and back on will sometimes bring the cluster back on and the wench will work. I really hate to wire it straight off the battery. The cluster I can live without but the winch I need for the snow plow. Thanks for the responses. I welcome ANY suggestions. Could there be a loose wire in the ignition switch wiring plug?

 

You just have to trace the wiring,plus the switch can be shorting out,have replaced em before,you can try to ohm the switch out also. OPT

 

It sounds like an intermittent short to me.
Good luck!