My 1999 Warrior is blowing fuses when warm. It goes something like this: Everything works fine until the machine is warm. Then I notice the nuetral light and reverse light don't light, unless the headlamps are on. Then I shutdown the machine and poof! a blown fuse. I can shut it down with the main switch or handlebar switch. I can leave the headlamps on or off. The result is the same. Once the nuetral and reverse lamps quit working unless the headlamps are on, a blown fuse is guaranteed once I shut it down. I can still run fine with lamps and headlights once the lamps start acting up, as long as I don't turn the machine off. It doesn't seem like a short in a wire to me. I was thinking maybe some corrosion at a specific connector or a module going south. Any advice???? I asked this question a few days ago with no feedback. There's got be an electrical guru out there somewhere! Thanks.

 

Sorry, I'm no guru, but it sounds like a short somewhere, corrosion, or a loose connection. Have you traced all your lines and done a ran a meter on them?

 

IT BLOWS A FUSE WHEN YOU SHUT IT OFF WITH THE BAR SWITCH? AND THE IGN.? OR JUST THE BAR SWITCH?

 

CHECK THE IGN. FIRST RUN A OHMS TEST ON THE IGN... TEST THE [ON ]TERM THAN TEST THE OFF.. SIDE.. THE METER SHOULD READ 0.00-0.0011 WHEN ITS ON AND YOU SHOULD GET SOME RESISTANCE IN THE OFF POSITION. BUT VERY LITTLE WHEN IT IS ON..

 

Definitly a short!!! The only issue is to find it. better get an OHM reader/multi meter. Either a switch, module or functioning elecrtical part can have a short inside of it (it's failure mode) or a wire or connector can simply be shorted out. I would check the switches on the bar as it seems may more people have found electrical problems there.

 

Theres a wiring harness, that comes out of the motor, on the stator side. Theres probably a wire, that is shorting, or the stator itself, is faulty when hot.