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Help! Hub safety-hour meter switch problem

Texjpr

By Texjpr
in Polaris UTV SxS Forum

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Texjpr Newbie

Texjpr

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2002 ranger 500 4x4 stopped running and wouldn't restart. Service manual wiring diagram helped identify the hub safety switch as the culprit. Using jumper wires to bypass  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?

Texjpr Newbie

Texjpr

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Thanks for the link Travis, but I'm dealing with an odd ball ranger. The VIN indicates a 2002 series 11. My service manual doesn't show a 2002  4x4 wiring diagram for it. It shows starting in 2003 which matches up with what I'm seeing under the hood.  Polaris customer service can't find a 2002 diagram. In addition, the VIN has only 16 alpha/numeric characters, not the 17 required for customer service. Jumper wiring it to bypass this switch concerns me because it feeds the alternator control switch. Don't want to fry other components. 

Nate T. Contributor

Nate T.

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A switch is just that - it let's voltage pass or it doesn't.  If the full-time on bothers you with a jumper, just put a $1.99 rocker switch inline with it.  Turn it on when you're ready to drive, off when you park it.  

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