You either have something overloading the circuit, or an exposed wire randomly coming into contact with a ground. What electrical accessories do you have on the machine, and what are they wired to? When you say "key" fuse....do you mean the main IGN fuse, or the ACCY fuse?

Here's a 2019 service manual, don't think much changed from 17-19

2019_polaris_rzr_xp_1000_xp4_1000_service_manual_9929417.pdf

drive.google.com

 

2019 fuse box was relocated on the 2 seaters. Not sure about the 4 seater. I reviewed the fuse box. It appears the only 10 amp fuse is fuel pump, lights, and awd. There is no keyed ACC for that year?

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when I remove the rear seat to access my fuses the label on the fuse box cover is marked KEY 10AMP and my 2017 operators manual has the same label name "key" and lists the function (keyswitch, star 1 relay coil, EPS, AWD switch, speed sensor, EPS relay coil, fuel pump relay, fuel pump, ECM).

 

I don’t know if that is the same circuit that powers the ACCY pole on the bus bar under the hood, but that’s my first guess. Do you have accessories such as lights bars, heated seats, stereo system, radio/intercom, etc?

If they are wired to the accy power at the bus bar, it could be that.


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I don’t know if that is the same circuit that powers the ACCY pole on the bus bar under the hood, but that’s my first guess. Do you have accessories such as lights bars, heated seats, stereo system, radio/intercom, etc?

If they are wired to the accy power at the bus bar, it could be that.


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X

 

Update on my fuse problem, I do want to thank everyone who chimed in to help. I took everyone's advice as to looking at the wiring diagrams, to taking all the added accessories off the bar under the hood. I started from square one and found a chafed wire under the heat shield located above the exhaust pipes. It was an error tying up the loom made by the assembler/assemblers. no more blown fuses

 

Glad you figured it out!


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Congratulations on finding it! There is a reason that folks should not just keep putting in bigger fuses. Wiring can be a bugger to trace out, but it is rewarding (if) when you finally find a definitive fix.

The other thing that we should take away from this is that we should make a serious effort to inspect our machines for things like this- wiring that may hang loose, hoses that are moving around, shields that have vibrated loose, etc.

 

Nicely done!