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By Texjpr
2002 ranger 500 4x4 stopped running and wouldn't restart. Service manual wiring diagram helped identify the hub safety switch asĀ the culprit. Using jumper wires to bypassĀ switch allowed the engine to start and run normally. Inspection of switch showed melted epoxy and a strong smell of burnt electrical. Unable to find replacement part either used or new. Is there a work around other than jumper wiring?
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By hdtran
That's the question! Or, if you want to add details:
(a) How do you use the UTV? (roads? off-road to get to trees? etc.)
(b) If you are wearing a helmet--how frequently? What type of helmet?
Ā
My own answers: (a) Most of the time off-road to get to downed trees, cut the trees to logs and haul the logs back for splitting. (b) Very rarely, a ski helmet and not a motorcycle helmet.
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By FGT
QUESTION: How to wire the C/B into this current dual battery set up.
EXISTING SITUATION: MAIN Battery is OEM and feeds OEM circuits. Added an AUX Battery in the OEM dual battery location. Connected the AUX - terminal to the MAIN - terminal. Connected the 100A Accessory Fuse Block power cable to the AUX + terminal. Installed a smart isolator between AUX and MAIN batteries where a cable from AUX + goes to the isolator and a cable from isolator to MAIN battery + terminal. Installed separate QD battery tender cables to both AUX and MAIN batteries + and -. The dual battery system appears to work as intended. For this Phase 1 improvement, to avoid having to constantly pull the leads on the AUX + battery post off and put on, for testing or maintenance of Accessory circuits, I wanted a more convenient and safer way to open the circuit from the AUX battery + terminal the Accessory Fuse Block. I called an off road dealership and was told to install a much larger capacity circuit breaker than the 100A rated Fuse Block and was recommended to get a 250A C/B like the one in the pic, which I did. I was told the reason for the C/B high amp rating was two-fold (a) to trip in the event of a battery short circuit and (b) to be able to conveniently open the C/B to kill power to the Accessory Fuse Block without removing leads from the AUX + terminal. The 250A C/B has two posts labelled "BAT LOAD" and "BAT LINE". There are currently three connections to the AUX + post: (1) Accessory Fuse Block power cable, (2) cable to Isolator AUX in terminal, (3) cable from AUX battery charger.
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By sxr951
corrosion had its oring neck areaĀ jammed in.. and besides that had corrosion in the starter just shorted when ran direct jumper cable to the starter post power to it
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By Pop Bob
After 10 hours of use, my machine had developed a low speed brake squeal. I removed the brake assembly and discovered that everything was put together dry. Not even lubrication on the caliper pins. After lubricating and reassembly, the squeal has disappeared. I will do the other three wheels today. Also, all grease fittings were under-greased (if at all) based on the amount of grease filled before they purged. This includes the drivelines. Next- I found many screws which were loose and/or stripped. I was able to tighten or fix them with my tap and die set. The lower a-arms on the front do not have grease zerks. I will remove the arms and install some. I guess Iām not surprised or even disappointed. These are just things that should be looked at on any machine. One thing I am pissed about though, is this āweld from hellā on the front . Totally unacceptable. For sure there will be water entry and eventual internal rust.Ā
(see photo) I will fix it. I did an oil and filter change which some of you will say was not necessary. But break-in time is when you are most likely to have contamination from production and initial wear-in. BTW there was some metal in the filter. Cheap insurance to change often. Engine access is very difficult on this machine compared to other Ā models. You have to remove lots of stuff to get to it. But I still like the machine very much, and Iām having a ball with it. Future plans include lights, cab enclosure and heater. Winters are long in Northern Michigan.Ā
PB
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