You the Man my friend, I've been messing with this problem for several days, even went out and bought a 2-year Duracell Battery which didn't help. After watching your video I went out and at first, nothing happened but kept sliding the switch back and forth a few hundred more times and the cluster started working and the machine started right up. Thanks a million, my friend.
Yep , I’ve taken a 1958 tote a goat apart that the bad old grease was actually only think holding it together lol sometimes they just can’t be put back like humpty dumpty
Not sure why, I went through 5 killswitches and they all had this issue, But where my contact was stuck, was also melted, I use cheap switches, Is the switch or the fourwheeler to blame?
I bought new switch cause the run button would not go up anymore. Now sometime the neutral light goes off and I have to keep moving everything. The run switch, the wires everything and then the N light will finally come back on. IDK what the problem is. Any ideals?
I'd check the green ground wires around were u plugged the run switch in . If there the round plugs . Mabey spin them or pull out n put back . The neutral switch is usual in the left side case by the stator near the gears . Sometimes like 3 or 4 wires check that plug also . You have a sensor that detects neutral that may be getting wore . But I'm stearing towards a ground first ! Will it start with the light on and off ?
I've seen wires get jerked n one wire come loose from a plug . Usually you can see the metal firing sticking out the back of the plug when this happens or it will look different . Usual u can tell it got pushed out
@@WaldensWorld Yes it will start when the light is on but I have to unplug a black wire coming out of my CDI box to get spark for it to start. It will not shut off after I unplug that black wire to get it to start. As so as I plug that black wire back in it kills the motor. Not sure what that means. Any thoughts on that issue? It's a 1999 Scrambler HO 500 4x4. It has been sitting for 8 years and I am just trying to get everything working right on it before riding. I will check the wires on the switch tomorrow like you said too. It has been a pain to get running. Tank had bad gas in it. So I drained it and cleaned it out. Carb was bad do to the bad gas from sitting so long. Replaced it and the fuel filter. Then it stopped getting fuel. I thought it was the fuel pump and replaced it. Still no fuel. Checked the lines and they was a fuel line that was crimped. Replaced fuel line and got fuel. Then I checked and changed spark plug because it would spark one time and not spark again. New plug did same thing. Found video that said to unplug the black wire coming out of the CDI box. Video didn't tell what the problem was nor how to fix the problem so you don't have to unplug that black wire. I don't know if it means the CDI box is bad or what. I just want to get it fixed so I can have my son riding with me. Sorry for writing a book. Just try to give you all the details so to better help you help me. Again thanks. Hope you can help me with this issue too.
My pod cluster won't illuminate. Machine starts fine, kill switch works fine. My machine is a 2004 1/2. They went to this electronic instrument pod 1/2 way through the production year. Any ideas where to start? @Walden's World.
@@Z-Bart check fuses then I'd grab a bolt meter . I'm guessing there should be a relay to turn in main power check fuse close to it ! Check grounds also plugs can jiggle open !
@@WaldensWorld Mouse nest. One brown and one yellow wire chewed through. Found a three bundle (blue, green, brown) white plastic plug end, have no idea what it plugs into. Once I spliced the brown and yellow everything working as it should. Thanks!
You the Man my friend, I've been messing with this problem for several days, even went out and bought a 2-year Duracell Battery which didn't help. After watching your video I went out and at first, nothing happened but kept sliding the switch back and forth a few hundred more times and the cluster started working and the machine started right up. Thanks a million, my friend.
Very welcome the thanks is why I do it I appreciate it hope you subscribed! Order new n let’s get to riding!
Just had the same problem with my 2006 Sportsman 450. Your video pointed me in the right direction. Thanks for the tips.
Did your 450 not have spark? Or was the gauge cluster not working? I'm guessing this is the issue with my 2005 450 also.
I have been riding mine with my thumb on the kill switch for 1/2 a year; I guess its time it fix it. Thanks for the tip..
Was on a Trail and shut off bike this Video got me home so thx for makeing!!!
Your very welcome n good to hear hope you subscribe lol !
Thanks , really helped me out !
Good to hear your very welcome!
This good to know. So just jiggling the on off switch to get spark. Hmmm I bet thats the problem with my 2005 sportsman 450
I just had to fix mine today. Had that exact same problem.
Getr done !
@@WaldensWorld yep. I greased the crap outta all of it & slapped it back together.
I have been riding mine with my thumb on the kill switch for 1/2 a year; I guess its time it fix it. Thanks for the tip..
@@Wheelchair-bear no problem. Good luck
All you have to do is loosen the two bolts slide it a little bit and hit it with WD40 and work it in. Back to new.
Definitely get home that way but that dang china plastic don’t last in the sun
How to put the cluster back together
Be very carefull taking that switch. Apart,. Its a nightmare with tiny. Springs. And balls
Yep , I’ve taken a 1958 tote a goat apart that the bad old grease was actually only think holding it together lol sometimes they just can’t be put back like humpty dumpty
Not sure why, I went through 5 killswitches and they all had this issue, But where my contact was stuck, was also melted, I use cheap switches, Is the switch or the fourwheeler to blame?
May be switch , this would happen from bad connection normally did it get wet ? Dang china switches
@@WaldensWorld They are cheap, But I figured i would go with the 30 dollar option instead of 150 dollars, But maybe 150 dollars is the best way to go.
Check eBay for oem used
I bought new switch cause the run button would not go up anymore. Now sometime the neutral light goes off and I have to keep moving everything. The run switch, the wires everything and then the N light will finally come back on. IDK what the problem is. Any ideals?
I'd check the green ground wires around were u plugged the run switch in . If there the round plugs . Mabey spin them or pull out n put back . The neutral switch is usual in the left side case by the stator near the gears . Sometimes like 3 or 4 wires check that plug also . You have a sensor that detects neutral that may be getting wore . But I'm stearing towards a ground first ! Will it start with the light on and off ?
I've seen wires get jerked n one wire come loose from a plug . Usually you can see the metal firing sticking out the back of the plug when this happens or it will look different . Usual u can tell it got pushed out
@@WaldensWorld Yes it will start when the light is on but I have to unplug a black wire coming out of my CDI box to get spark for it to start. It will not shut off after I unplug that black wire to get it to start. As so as I plug that black wire back in it kills the motor. Not sure what that means. Any thoughts on that issue? It's a 1999 Scrambler HO 500 4x4. It has been sitting for 8 years and I am just trying to get everything working right on it before riding. I will check the wires on the switch tomorrow like you said too.
It has been a pain to get running. Tank had bad gas in it. So I drained it and cleaned it out. Carb was bad do to the bad gas from sitting so long. Replaced it and the fuel filter. Then it stopped getting fuel. I thought it was the fuel pump and replaced it. Still no fuel. Checked the lines and they was a fuel line that was crimped. Replaced fuel line and got fuel. Then I checked and changed spark plug because it would spark one time and not spark again. New plug did same thing. Found video that said to unplug the black wire coming out of the CDI box. Video didn't tell what the problem was nor how to fix the problem so you don't have to unplug that black wire. I don't know if it means the CDI box is bad or what. I just want to get it fixed so I can have my son riding with me. Sorry for writing a book. Just try to give you all the details so to better help you help me. Again thanks. Hope you can help me with this issue too.
My pod cluster won't illuminate. Machine starts fine, kill switch works fine. My machine is a 2004 1/2. They went to this electronic instrument pod 1/2 way through the production year. Any ideas where to start? @Walden's World.
If the rest of the cluster works I'd think your light was out ! Not sure if that's in the screen itself or external small light !
@@WaldensWorld No nothing works or lights up on the cluster. Also no 4x4 engagement.
@@Z-Bart check fuses then I'd grab a bolt meter . I'm guessing there should be a relay to turn in main power check fuse close to it ! Check grounds also plugs can jiggle open !
@@WaldensWorld Mouse nest. One brown and one yellow wire chewed through. Found a three bundle (blue, green, brown) white plastic plug end, have no idea what it plugs into. Once I spliced the brown and yellow everything working as it should. Thanks!
Without even watching the video yet I bet the kill switch is the problem . Its very common
U nailed it ! There were few other issues but yep I worked in it n the next week the switch went out ! Lucky he got home before turning it off !
Does a 2002 sportsman have a ecm?
All of them have ecm or cdi ! I think that year had issues with stator n ecm going out ! I have a600 I changed from ac ecm to a dc system !
Would this make the 4x4 not engage also
Different switch
Yes, The killswitch powers everything and this wont send power to the hub coils.