[kzr240]

Ok this is driving me nuts. I have a 16 xp 1k rzr with less than 15 hours on it. The bike keeps blowing the 10a key fuse. I took it to dealership and of course it didn't do it there. Here is the thing. It only does it in high gear. I thought maybe it was a rpm thing but even when I rev it high in low it doesn't blow. When this fuse blows it completely shuts the bike off till a new fuse is put in. I have blown over 12 fuses. Now it does seem to happen in wet conditions. It started when I was riding in the rain and now there is snow on the ground. I am at a total loss with this and don't even want to take it out cause of this issue. Can someone please get me started in the right direction?

 

[Dizzledog1]

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


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[pkrider]

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

 

[31851]

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

 

[kzr240]

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.

 

[pkrider]

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.

 

[kzr240]

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.

 

[pkrider]

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.

 

[kzr240]

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.

 

[Jay Dirt]

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..

 

[wrightnow]

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...

 

[Oasis04]

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.

 

[kzr240]

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.

 

[kzr240]

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.

 

[kzr240]

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.

Ok I'll go disconnect it all and give it a run.

 

[kzr240]

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.

 

[Clubin]

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

 

[kzr240]

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.

 

[pkrider]

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.

 

[kzr240]

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.