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Electrical Problems 2002 500 Sportsman

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Old Mar 10, 2013 | 08:22 PM
  #1  
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Default Electrical Problems 2002 500 Sportsman

High beam and instrument cluster work, no low beams or electric start, kill switch doesn't work either. What should I check first? Getting only 5 amps at the 20 amp circuit breaker, how many should I see?
 
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Old Mar 11, 2013 | 06:18 AM
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You're getting power to the speedo and high beam by means of the main circuit breaker and left control switch,but plenty of circuit breakers have corroded in the pouch.Just slice the plastic pouch open and check the terminals. If corroded replace at any auto store. Jump the solenoid to see if the starter works. Sounds like the main problem probably is in the left control switch especially if there is no voltage to the low beam connectors(and you've eliminated any connection problem under the front panel) Pull the two connections at the switch,clean and use electrical grease and see if this helps. If it doesn't, trace the wiring from the left switch into the pod area for shorts. Not uncommon for the left switch soldered contacts to come loose from vibration. I've repaired/replaced a few of them over the years.
 
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Old Mar 11, 2013 | 07:42 AM
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Default Pouches

Will try today, thanks. What is the best way to reseal pouch?

Thanks again.
 
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Old Mar 11, 2013 | 09:24 AM
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I always just squirted in some dielectric grease or silicone around the terminals on the new circuit breaker and wrapped the pouch in electrical tape.
 
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