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Big electrical issues - 8/27/2008 10:00:34 AM

Bigdaddypo

Posts: 8
Joined: 8/6/2008
Status: offline

I have recently had my instrument cluster go out on me. Completely blank. No lights or anything. As a result, the awd doesn't work anymore. Found that out the hard way. I had noticed the rpm's jumping around a lot while idleing before it quit. Also, before the last time I rode it, the battery was completely dead when I went to start it. Charged it right up and it started fine.

So I've checked the cluster wiring as per service manual; pins 1&8 and 2&8 for 12 volts. Got it, so they say replace the cluster. ~$300 hit, ouch.

Now I'm trying to check the stator and voltage regulator for reasons the cluster fried. The manual says to check the three coils of the stator for resistance with each other. It's supposed to be 0.19ohms between each coil. I read 0.7ohms across each set. Am I doing something wrong? Also, is there a way to check the voltage regulator off the quad? It's looking to get to be quite an expensive repair if I have to start replaceing these things. Has anyone had problems with these components?

Also, looking at the wiring diagram, there looks to be a way to bypass the speedo for awd. Does anyone know if the speedo changes the voltage or pulses the signal or anything to the fornt diff. I'm thinking that the current only passes through the speedo to indicate the awd symbol on the display. Otherwise, because the front diff is electronic over mechanical, I should be able to directly run the wire from the switch to the front diff. Anyone ever try this before?

Thanks all.

_____________________________

05 SP800
1.5" front lift
1" front spacer
Kenda Executioner's
27x10 Front
27x12 Rear
Power Commander III

Post #: 1

RE: Big electrical issues - 8/27/2008 7:15:07 PM

MRMARIO2U

Posts: 4246
Joined: 10/9/2004
From: PARK HILLS MO.
Status: offline

I WILL SAVE YOU SOME CASH AND SELL YOU A GOOD USED CLUSTER. $125 SHIPPED IN THE US.

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(in reply to Bigdaddypo)

Post #: 2

RE: Big electrical issues - 8/27/2008 7:32:04 PM

425 Xpedition

Posts: 991
Joined: 4/26/2000
From: Crosby, TX
Status: offline

Ground the Brown/white wire and the AWD will work when the switch is on.

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Pictures

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Post #: 3

RE: Big electrical issues - 8/27/2008 10:20:47 PM

sfd_324

Posts: 357
Joined: 1/24/2008
From: Sylacauga, AL
Status: offline

Cluster......we might need it if he don't take it!

(in reply to MRMARIO2U)

Post #: 4

RE: Big electrical issues - 8/27/2008 10:51:40 PM

mudman3298

Posts: 269
Joined: 1/17/2008
From: Humble, Tx
Status: offline

might sound stupid but did you check the fuses? when my pod quit working on me it was because of a fuse

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2007 SPORTSMAN 500
Dirtbmw20 RADIATOR BRACKET
29.5 LAWS
TURNER AXELS IN BACK
HSP PIPE
1.5 IN SPACERS
2IN PUCK LIFT
CUSTOM SNORKELS

(in reply to sfd_324)

Post #: 5

RE: Big electrical issues - 8/28/2008 10:20:01 AM

Bigdaddypo

Posts: 8
Joined: 8/6/2008
Status: offline

Thanks all,

SFD, go ahead. I picked up a used cluster and voltage regulator here. Put the regulator in and thought I'd try the original cluster for the heck of it.

What do you know! Everything works perfect. Stupid regulator. SO now I have a spare cluster.

Also, I figured out my dead battery issue. Seems my heated grips and throttle have a small draw for some reason. Disconnected them and no more draw.

Thanks all.

_____________________________

05 SP800
1.5" front lift
1" front spacer
Kenda Executioner's
27x10 Front
27x12 Rear
Power Commander III

(in reply to mudman3298)

Post #: 6

RE: Big electrical issues - 8/28/2008 1:18:31 PM

Foulplay

Posts: 1717
Joined: 11/27/2006
From: La Porte, TX
Status: offline

quote:

ORIGINAL: mudman3298

might sound stupid but did you check the fuses? when my pod quit working on me it was because of a fuse

There are no fuses on the twins...

_____________________________

'06 Popo 800 EFI on 29.5" Outlaws

'05 Popo 700 carb on 29.5" Outlaws

'07 Popo 500 H.O. EFI (hers) on 27" Outlaws

'78 Jeep CJ-7 w/304 V8

http://s125.photobucket.com/albums/p44/Foulplay_photo/

This Honda's gone...
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(in reply to mudman3298)

Post #: 7

RE: Big electrical issues - 8/28/2008 1:25:45 PM

riblet

Posts: 381
Joined: 1/23/2008
From: Katy, TX
Status: offline

quote:

ORIGINAL: Foulplay

quote:

ORIGINAL: mudman3298

might sound stupid but did you check the fuses? when my pod quit working on me it was because of a fuse

There are no fuses on the twins...

I have 4 fuses on mine right where the radiator cap used to be underneath the front box.

_____________________________

06 Polaris Sportsman 800 EFI
29.5 Outlaws
Viper winch w/ green amsteel
2" lift
1" spacers
snorkel in pod
rad relocate
split audiopipe
RD Bar Ends
RD fairlead
Death Grips

(in reply to Foulplay)

Post #: 8

RE: Big electrical issues - 8/28/2008 1:33:25 PM

Foulplay

Posts: 1717
Joined: 11/27/2006
From: La Porte, TX
Status: offline

quote:

ORIGINAL: riblet

quote:

ORIGINAL: Foulplay

There are no fuses on the twins...

I have 4 fuses on mine right where the radiator cap used to be underneath the front box.

I know what you're talking about, I have those too, but they are not fuses. They are circuit breakers that reset themselves.

_____________________________

'06 Popo 800 EFI on 29.5" Outlaws

'05 Popo 700 carb on 29.5" Outlaws

'07 Popo 500 H.O. EFI (hers) on 27" Outlaws

'78 Jeep CJ-7 w/304 V8

http://s125.photobucket.com/albums/p44/Foulplay_photo/

This Honda's gone...
http://video.yahoo.com/watch/341841/2183512

(in reply to riblet)

Post #: 9

RE: Big electrical issues - 8/28/2008 1:41:10 PM

SouthBossierGrizz

Posts: 2235
Joined: 1/27/2004
From: Bossier City, LA
Status: offline

There are fuses on the twins, my 07 and 08 have a fuse block, with four fuses, not circut breakers.

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#7

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Yep, I SUCK!

2008 Polaris 800 H.O. (Zookeeper II)
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(in reply to Foulplay)

Post #: 10

RE: Big electrical issues - 8/28/2008 1:46:02 PM

Foulplay

Posts: 1717
Joined: 11/27/2006
From: La Porte, TX
Status: offline

quote:

ORIGINAL: SouthBossierGrizz

There are fuses on the twins, my 07 and 08 have a fuse block, with four fuses, not circut breakers.

Okay, I'm sorry then. Mine look more like a small relay than they do a fuse. They are about the same size as a fuse though. Which Popo is it that doesn't have fuses then?

_____________________________

'06 Popo 800 EFI on 29.5" Outlaws

'05 Popo 700 carb on 29.5" Outlaws

'07 Popo 500 H.O. EFI (hers) on 27" Outlaws

'78 Jeep CJ-7 w/304 V8

http://s125.photobucket.com/albums/p44/Foulplay_photo/

This Honda's gone...
http://video.yahoo.com/watch/341841/2183512

(in reply to SouthBossierGrizz)

Post #: 11

RE: Big electrical issues - 8/28/2008 1:53:25 PM

ouch1175

Posts: 123
Joined: 7/17/2007
From: Mt. Pleasant Tx.
Status: offline

I don't think my 500 has fuses. If it does I sure haven't been able to locate 'em. Now in addition to that, if I do have them on the 500 and someone can correct me please do.. And let me know where they are..

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Post #: 12

RE: Big electrical issues - 8/28/2008 2:08:40 PM

Foulplay

Posts: 1717
Joined: 11/27/2006
From: La Porte, TX
Status: offline

quote:

ORIGINAL: ouch1175

I don't think my 500 has fuses. If it does I sure haven't been able to locate 'em. Now in addition to that, if I do have them on the 500 and someone can correct me please do.. And let me know where they are..

Okay maybe it is my 500 that I'm thinking of that doesn't have fuses...I know one of them doesn't.

_____________________________

'06 Popo 800 EFI on 29.5" Outlaws

'05 Popo 700 carb on 29.5" Outlaws

'07 Popo 500 H.O. EFI (hers) on 27" Outlaws

'78 Jeep CJ-7 w/304 V8

http://s125.photobucket.com/albums/p44/Foulplay_photo/

This Honda's gone...
http://video.yahoo.com/watch/341841/2183512

(in reply to ouch1175)

Post #: 13

RE: Big electrical issues - 8/28/2008 2:34:41 PM

Bigdaddypo

Posts: 8
Joined: 8/6/2008
Status: offline

Your're right, Foulplay. My 05 800 doesn't have fuses either. Looks like a fuse block beside the rad cap. You could probably put fuses in there if you wanted, but I've got the thermal type circuit breakers as well.

_____________________________

05 SP800
1.5" front lift
1" front spacer
Kenda Executioner's
27x10 Front
27x12 Rear
Power Commander III

(in reply to Foulplay)

Post #: 14

RE: Big electrical issues - 8/28/2008 5:34:13 PM

conmann

Posts: 89
Joined: 11/30/2007
From: Dayton, TX
Status: offline

This happened to my 800. I replaced the 5 amp fuse and it started working. Had the same problems, no cluster, no 4wd. Just pull it out spray some cleaner in there and it should be ok. I just had another problem with the fuse block so I cut it out and wired in some circuit breakers into the wiring harness. It is working good and you don't ever have to mess with fuses again

_____________________________

800
29"s
lift
spacers
bumpers
winch
huge ice chest
hottie on the back
snorks in the box

(in reply to Bigdaddypo)

Post #: 15

RE: Big electrical issues - 8/28/2008 9:38:10 PM

RBarnett95

Posts: 26
Joined: 3/22/2008
Status: offline

only the 500 have no fuses.. 700 and 800 have a 3 fuses and 1 cuircut breaker.. Not to inlcude like 10 fusable links which act just like fuskes

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05 PoPo 700 28" Mudlights, 2" lift, Big Radio, Lots of lights

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Post #: 16