2000 xplorer 250 I noticed today while plowing that my 4wd stopped working and won't engage, but when that happens the head light shuts completely off and I hear a click somewhere i think towards the back by the battery. I let the quad sit for a while and everything works again but after about 20 min of plowing it happens again. Is something resetting or could something be loose? I can tell if the 4wd is going to work if the head light comes on when I start it. Help!

 

Sounds like the 20 amp circuit breaker in the sealed pouch up from the battery is getting hot and shutting off. Designed to do this if there is too much load,but age,corrosion can do the same thing. You can slice the pouch open and check the breaker terminals out.If corroded as many are just replace it at any auto store and silicone and tape the pouch back up. Item #5 Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse Not a bad idea to check the battery connections also.

 

Thanks old polaris tech. Everything you suggested worked. All it took was a $3.79 circuit breaker and clean battery terminals. Thanks for saving me time and money!

 

Cheap fix. Glad that solved the problem.