Check your seal on your fuse box. It could be pinched


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Do you have any aftermarket items hooked up to your vehicle at all? If so what items?

 

sounds like a short. bare wire touching something, or a connector.

 

The only after market things I have hooked up is the fog lights and a light bar. Now I remind you that it only blows in high gear so if it was one of the lights it should blow in low gear as well.

 

Was this happening before you installed the light bar? Where did you hook up the light bar to? Try disconnecting the light bar to the power source and see if that doesn't solve where the problem is.

 

I also put a winch on and ran a factory harness to the buss bar under the hood. This is where I hooked the light bar up to as well. This is connected straight to the battery so this leads me to believe it's not even tied into the system. I could disconnect it but don't think it will matter. No the bike wasn't doing this before the fog lights or light bar but also put 75 miles on it afterwards and never had a problem. The owners manual says the key fuse is tied into gauge, efi relay coil, eps relay coil, and key switch. I just don't understand how it does it in high gear only. I wish I had a wire diagram to track all these to check wires and grounds.

 

Someone else can chime in as well, but I think that's where you problem is tying it on to the factory buss bar. You may be overloading it. If you haven't you should install a separate distribution box since you already have a separate power source coming from the battery.

 

It can't be. The winch comes with a separate oem harness that goes strait to the battery to the buss bar. So the only things on that circuit is the winch and light bar that go straight to the battery. And the fuse blows only in high gear with light bar and winch off. Both of these are completely separate from the rest of the bikes electrical system except being tied to the battery.

 

On my xp4 with zero miles I found the main wire harness was laying on the front driveshafts u-joint (under the center console about where the rear passenger feet go), I'm sure that would have caused me strange electrical problems in short time.., might be worth a look if you have it apart..

 

Seems to be all clear of driveshaft and secured. Thanks for the suggestion.

 

trouble shooting 101, dis-connect the new harness at the battery and anything else thats been added since this started happing.

Right now your looking to eliminate the new stuff and then see what happens.

Good luck...

 

The key is connected to the bus bar acc. post
take the winch off the factory under dash bus. even if that not where problem lies.

 

Ok I'll disconnect it all and run it real fast.

 

Ok disconnected the buss cables going to battery from winch and light bar and the wires going to the accessory post from the buss. I also pulled the head light fuse to take them out of the equation as well. Took it for a spin not even a half mile and blew 2 key fuses in high gear and then I blew one for the first time in low gear. I wonder if it's the voltage rectifier? The D.C. On gauge is reading 14.1-14.3 when running.

 

Glad you eliminated the aftermarkets. Could be something in your VR. I agree , take back to dealer.

 

Take it back to the dealer. Something is shorting it out. Maybe in the harnes.

 

I have been talking with dealer and they have emailed Polaris to see what they comeback with. I would just rather fix it myself if I can to alleviate having to take it to them and the time for them to fix it. I'm a certified aircraft mechanic and rather do the work myself and have them pay for the parts if needed. I just don't have the test equipment to test all these atv parts.

 

Did you figure this out? I'm experiencing the exact same thing on my 17.

 

ok since it was still under the 6mo warranty they covered it. I felt like I knew more about this stuff than their own mechanics. Anyway. Every time I took it to them it stopped. I think it was moisture related and only did it after getting wet. So I had to take it back to them multiple times and took the blown fuses to them to. I had about 15 of them. Then I had to drive it with them in it till I got the headlight to flicker and the govenor kicked with seat belt on. Anyway I told them the only thing I could find on line of the same issue was they replaced the whole wiring harness of the bike and they did and I have taken it out 3 times and haven't had any issues. Hope ur still in the 6mo warranty and bought the extended warranty. The Harnes cost 950$.

 

I am having the same problem with my son's 2021 RZR 1000sm, driving me crazy. The key fuse blows at random times, sometimes in water but not always. ANY SUGGESTIONS

 

some units have wire chaffing from the long heat shield above the catalytic converter (on the trunk plastic).If the wire is touching the heat shield... its probably chaffed. tape it up and zip-tie it away from the shield.