Failed key switch, melted grund wire - Again! - Polaris ATV Forum
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post #1 of 12 (permalink) Old 08-16-2018, 02:06 PM Thread Starter
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Failed key switch, melted grund wire - Again!

Ok, so this is the second time this has happened! 2004.5 Sportsman 600 Twin. The first time was just over 2 years and 60hrs ago. Parked and shut the machine off for lunch and white smoke came out under the hood. No power to anything. Got it home and found that the key switch had shorted from the v-reg wire to the brown ground wire. Melted the ground wire all the way to the connector under the hood. Replaced the ground wire and switch ($85 from Polaris), tested everything I could think of and moved on.

Fast forward to last weekend in the middle of the trail. Key switch started acting up. It would start but as soon as I let off the switch it would stall. If I held the switch between run and start if would stay running and after a while I could let go and ride the machine. Until it stopped on the trail and I got a puff of smoke from the headlight pod. No power to anything. Pulled the pod and found the ground wire melted again. Towed out and home. Same issue. Switch is shorted and the brown wire melted.

I have included photos of the switch. I cut the part around the plug off the switch for the photos. I really don't want to go through this again. I plugged in a new switch and I have power. Once I get the ground wire replaced I will fire it up and test the charging system. Any suggestions would be helpful!
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Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2019 Sportsman 450. 26" Bear Claw HTRs on Moose 427X Wheels.

2007 Sportsman 500 EFI, Polaris Winch, 25" Bear Claws QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2017 Polaris Ranger 1000XP - Roof and front glass
2018 Kawasaki KLR650
2001 Magnum 325 Warn winch and Moose 60" plow-Sent to Daughter and Son-In-Law since his blew up
SOLD 2004 Sportsman 600 Twin
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post #2 of 12 (permalink) Old 08-16-2018, 03:28 PM
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Steve, just wondering why that switch needs a ground wire? Doesn't the ignition just control the positive side of things? I could see if it had 2 ground wires (one in one out) just don't know why the ignition switch opens a ground circuit? Switch mounts into the plastic pod hole and no way does that switch have any connection to ground through the mount? Have you looked at the wire diagram for ur bike, and does it have that ground wire listed? Did a PO maybe install it and it don't belong there?



JUNE 2017 & SEPTEMBER 2018 POLARIS FORUM ATV OF THE MONTH WINNER

2019 Sportsman 850 SP Premium

Removed all Warning Decals
3500# Polaris Winch W/Synthetic Rope
Winch Stopper Cable Line Saver
ATV-GURU.COM Front and Rear Bumpers
2" Receiver in Front Bumper
Kenda K587 HTR Bear Claws 26X9X14 & 26X11X14
Ultimate Series Windshield Fairing, Mid & Low Height Windshield
New Style Polaris Lock & Ride Rear Storage Box
Garmin GPS176C, Ram Mount
Polaris Rear View Mirrors
4" Front Rack Extender
Center Brake/Tail Light LED
Rear LED work lights/strobes



Built on March 27 2019
Purchased New April 13 2019 0.1 Hr .2 Mi
Power Sports Abrams, Wi





SOLD
2006 Sportsman 800 EFI Twin
Purchased new to me on Aug 08 2016 97Hr's 811Mi
Sold Apr 07 2019 231 Hr 3126 Mi



https://www.youtube.com/watch?time_c...&v=k6Nlb_qRoeg

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Last edited by FPD218; 08-16-2018 at 03:31 PM.
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post #3 of 12 (permalink) Old 08-16-2018, 03:40 PM
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Steve, did a quick google search, seems this is common on ur machine found this check it out

https://www.polarisatvforums.com/for...ss-newbie.html

also...

https://atvconnection.com/forums/pol...on-switch.html

Google search this " 2004 sportsman burned ignition ground wire " lot of things listed....



JUNE 2017 & SEPTEMBER 2018 POLARIS FORUM ATV OF THE MONTH WINNER

2019 Sportsman 850 SP Premium

Removed all Warning Decals
3500# Polaris Winch W/Synthetic Rope
Winch Stopper Cable Line Saver
ATV-GURU.COM Front and Rear Bumpers
2" Receiver in Front Bumper
Kenda K587 HTR Bear Claws 26X9X14 & 26X11X14
Ultimate Series Windshield Fairing, Mid & Low Height Windshield
New Style Polaris Lock & Ride Rear Storage Box
Garmin GPS176C, Ram Mount
Polaris Rear View Mirrors
4" Front Rack Extender
Center Brake/Tail Light LED
Rear LED work lights/strobes



Built on March 27 2019
Purchased New April 13 2019 0.1 Hr .2 Mi
Power Sports Abrams, Wi





SOLD
2006 Sportsman 800 EFI Twin
Purchased new to me on Aug 08 2016 97Hr's 811Mi
Sold Apr 07 2019 231 Hr 3126 Mi



https://www.youtube.com/watch?time_c...&v=k6Nlb_qRoeg

"I am the majority!"


*WEAR A HELMET, I'M LIVING PROOF THEY WORK!

Last edited by FPD218; 08-16-2018 at 03:47 PM.
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post #4 of 12 (permalink) Old 08-16-2018, 04:09 PM Thread Starter
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Thanks Jerry! The ground as far as I can tell is for the ETC in the throttle housing. None of the threads I have found say why it failed. They just indicate a failure of the key switch. Most have wired around the key switch or replaced it. Not sure if I am missing something that causes this or not. The first time was about 100 hrs after I got it. This time was 62hrs after the last time. Almost 1000 miles though.

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2019 Sportsman 450. 26" Bear Claw HTRs on Moose 427X Wheels.

2007 Sportsman 500 EFI, Polaris Winch, 25" Bear Claws QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2017 Polaris Ranger 1000XP - Roof and front glass
2018 Kawasaki KLR650
2001 Magnum 325 Warn winch and Moose 60" plow-Sent to Daughter and Son-In-Law since his blew up
SOLD 2004 Sportsman 600 Twin
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post #5 of 12 (permalink) Old 08-16-2018, 04:26 PM
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I seen one post referencing the fuel gauge? Does that ground wire work the fuel gauge circuit?



JUNE 2017 & SEPTEMBER 2018 POLARIS FORUM ATV OF THE MONTH WINNER

2019 Sportsman 850 SP Premium

Removed all Warning Decals
3500# Polaris Winch W/Synthetic Rope
Winch Stopper Cable Line Saver
ATV-GURU.COM Front and Rear Bumpers
2" Receiver in Front Bumper
Kenda K587 HTR Bear Claws 26X9X14 & 26X11X14
Ultimate Series Windshield Fairing, Mid & Low Height Windshield
New Style Polaris Lock & Ride Rear Storage Box
Garmin GPS176C, Ram Mount
Polaris Rear View Mirrors
4" Front Rack Extender
Center Brake/Tail Light LED
Rear LED work lights/strobes



Built on March 27 2019
Purchased New April 13 2019 0.1 Hr .2 Mi
Power Sports Abrams, Wi





SOLD
2006 Sportsman 800 EFI Twin
Purchased new to me on Aug 08 2016 97Hr's 811Mi
Sold Apr 07 2019 231 Hr 3126 Mi



https://www.youtube.com/watch?time_c...&v=k6Nlb_qRoeg

"I am the majority!"


*WEAR A HELMET, I'M LIVING PROOF THEY WORK!
FPD218 is online now  
post #6 of 12 (permalink) Old 08-16-2018, 04:31 PM
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Suggestion... when replacing that burned ground wire either fuse it or go around the ignition switch and go direct to the throttle housing?



JUNE 2017 & SEPTEMBER 2018 POLARIS FORUM ATV OF THE MONTH WINNER

2019 Sportsman 850 SP Premium

Removed all Warning Decals
3500# Polaris Winch W/Synthetic Rope
Winch Stopper Cable Line Saver
ATV-GURU.COM Front and Rear Bumpers
2" Receiver in Front Bumper
Kenda K587 HTR Bear Claws 26X9X14 & 26X11X14
Ultimate Series Windshield Fairing, Mid & Low Height Windshield
New Style Polaris Lock & Ride Rear Storage Box
Garmin GPS176C, Ram Mount
Polaris Rear View Mirrors
4" Front Rack Extender
Center Brake/Tail Light LED
Rear LED work lights/strobes



Built on March 27 2019
Purchased New April 13 2019 0.1 Hr .2 Mi
Power Sports Abrams, Wi





SOLD
2006 Sportsman 800 EFI Twin
Purchased new to me on Aug 08 2016 97Hr's 811Mi
Sold Apr 07 2019 231 Hr 3126 Mi



https://www.youtube.com/watch?time_c...&v=k6Nlb_qRoeg

"I am the majority!"


*WEAR A HELMET, I'M LIVING PROOF THEY WORK!
FPD218 is online now  
post #7 of 12 (permalink) Old 08-16-2018, 05:14 PM
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Steve I'm not completely familiar with your model so help me understand. If I'm reading correctly there is a pos+ 12vdc wire coming directly from the VR to the key switch?

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
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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!)
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2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
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post #8 of 12 (permalink) Old 08-16-2018, 09:26 PM Thread Starter
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Quote:
Originally Posted by bp405 View Post
Steve I'm not completely familiar with your model so help me understand. If I'm reading correctly there is a pos+ 12vdc wire coming directly from the VR to the key switch?
I have to look more closely at the wiring diagram. The wire does come from or go to the V reg. Not sure which way current goes though. Took a quick look at the diagram before I came inside. I will have to look at it more closely tomorrow. There are actually 2 wires in that pin connection at the switch but I don't remember where the other one comes from either.

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2019 Sportsman 450. 26" Bear Claw HTRs on Moose 427X Wheels.

2007 Sportsman 500 EFI, Polaris Winch, 25" Bear Claws QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2017 Polaris Ranger 1000XP - Roof and front glass
2018 Kawasaki KLR650
2001 Magnum 325 Warn winch and Moose 60" plow-Sent to Daughter and Son-In-Law since his blew up
SOLD 2004 Sportsman 600 Twin
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post #9 of 12 (permalink) Old 08-17-2018, 06:57 AM
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Stave, I have 3 wiring diagrams for 04 600/700 Sportsman's; built before 2/20/03, after 2/20/03 and late models with fuel gauge - all are the same in respect to the red and brown wires.

The red wire goes from the battery to the Vreg, from the Vreg to the accessory plug in the headlight pod, from the acc plug to the key switch - the brown wire from the acc plug goes to frame ground and the key switch.

I would suspect a defect in the acc plug causing the problem or a faulty main switch design
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post #10 of 12 (permalink) Old 08-17-2018, 10:34 AM Thread Starter
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Quote:
Originally Posted by latebird View Post
Stave, I have 3 wiring diagrams for 04 600/700 Sportsman's; built before 2/20/03, after 2/20/03 and late models with fuel gauge - all are the same in respect to the red and brown wires.

The red wire goes from the battery to the Vreg, from the Vreg to the accessory plug in the headlight pod, from the acc plug to the key switch - the brown wire from the acc plug goes to frame ground and the key switch.

I would suspect a defect in the acc plug causing the problem or a faulty main switch design
Mine is the later one with the fuel gauge. Since I haven't been able to find any reason for the failure I thing it is the main switch design. This time I ordered a repair kit that includes the new switch and a pigtail wire harness with a new plug. I also got an extra switch. I think I will put a fuse in the ground wire so if it does happen again, all I will have to do is replace the switch and a fuse instead of a whole wire. A repair that could be done on the trail if needed.
FPD218 likes this.

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2019 Sportsman 450. 26" Bear Claw HTRs on Moose 427X Wheels.

2007 Sportsman 500 EFI, Polaris Winch, 25" Bear Claws QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2017 Polaris Ranger 1000XP - Roof and front glass
2018 Kawasaki KLR650
2001 Magnum 325 Warn winch and Moose 60" plow-Sent to Daughter and Son-In-Law since his blew up
SOLD 2004 Sportsman 600 Twin
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