Where is the brake Switch?! - Polaris ATV Forum
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post #1 of 14 (permalink) Old 08-19-2019, 03:36 PM Thread Starter
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Where is the brake Switch?!

I have a dead short related to the brake switch and the tail light connector on my 1999 Sportsman 500 Big Boss, 6x6.

You would think the brake switch would sit right there on the left caliper. . . but it doesn't. Where in the world is this thing? It shows up on the electrical diagram but I can't find it. It must be somewhere near a brake right?!
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post #2 of 14 (permalink) Old 08-19-2019, 03:45 PM
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On the "fire wall" if you will. It's also the distribution block or proportioning valve.

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
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post #3 of 14 (permalink) Old 08-19-2019, 03:49 PM Thread Starter
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Sorry. Could you be more specific. Firewall? I got one of those on my cars and trucks but. . . hmmm.
What do I have to remove to access it? Take the plastic off the two sides and front area. . . find it in front of the main headlight?
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post #4 of 14 (permalink) Old 08-19-2019, 05:32 PM
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Number 23 in the diagram. Its a pressure switch that screws in the brake distribution block on the bulkhead that holds the steering shaft. Yep, you have to remove the plastic under the headlight pod and maybe the tank to access it. Just follow the brake line from the left hand lever MC and it will lead you right to it. Here's a picture of what it looks like.

https://www.ebay.com/itm/95-98-Polar...cAAOSwFdpbR5~K
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post #5 of 14 (permalink) Old 08-19-2019, 05:58 PM
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I said "firewall" if you will! You have to bring something to the table here!!!! Like polman said bulk head. It's under the pod on the frame!!! In front of the steering post!!!! Follow the brake lines!!! Distribution block/proportioning valve!!!!! You'll see an electrical connection that's your switch!!! C'mon man!!!!!!! You want me to come over and point it out with a lasar pointer?????

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
bp405 is online now  
post #6 of 14 (permalink) Old 08-20-2019, 08:54 AM
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Damn, bp405 woke up grouchy this morning

What brought you to the conclusion that you have a dead short? It is blowing a fuse, tripping a breaker or the brake light is on all the time?

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post #7 of 14 (permalink) Old 08-20-2019, 09:22 AM
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Quote:
Originally Posted by latebird View Post
Damn, bp405 woke up grouchy this morning

What brought you to the conclusion that you have a dead short? It is blowing a fuse, tripping a breaker or the brake light is on all the time?
First of all it was yesterday!!! Second there AIN'T NOBODY on this site as grouchy as your ancient ass!!!! Third I'm just breaking chops.

Latebird stop being such a pansy this a MANS site!!!!!

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
bp405 is online now  
post #8 of 14 (permalink) Old 08-20-2019, 09:58 AM
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Quote:
Originally Posted by bp405 View Post
Quote:
Originally Posted by latebird View Post
Damn, bp405 woke up grouchy this morning

What brought you to the conclusion that you have a dead short? It is blowing a fuse, tripping a breaker or the brake light is on all the time?
First of all it was yesterday!!! Second there AIN'T NOBODY on this site as grouchy as your ancient ass!!!! Third I'm just breaking chops.

Latebird stop being such a pansy this a MANS site!!!!!
LOL, Dang! Latebird, I think you hit a nerve.
Bp, I'm not sure where I came up with the "bulkhead" moniker but I think I saw it somewhere in a service manual. I never really knew what to call that frame part that holds the steering shaft, electronics and brake splitter. It does basically serve a similar purpose as the firewall in an auto.
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post #9 of 14 (permalink) Old 08-20-2019, 10:36 AM
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I guess he woke up grouchy yesterday too

Call it a bulk head or fire wall or steering post mount support gusset - whatever, we all know what we are talking about

Shop Owner and Mechanic with over 50 years experience
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post #10 of 14 (permalink) Old 08-20-2019, 10:36 AM
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See here I thought we were all just a big internet Polaris forum family!!!! I'm just busting them fellas!!!

Listen latebird and polman I call you guys old cause what else do I have????? You guys have forgotten more then I know!!!!

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
bp405 is online now  
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