2005 TRV 500 Electrical Help!

[Bxcall1]

My 2005 TRV 500 quit on me today. No power to start, no 4x4 shift, no winch, no dash light, but the headlight go on. I’ve checked the fuse marked “main” which was ok.

There are 2 relays and 2 diodes in the fuse box. Could one of those cause my problem?

[Bxcall1]

In better light and with better eyes my son determined that the ignition fuse is blown. He replaced it, which lasted about 30 seconds. Guess I’m chasing wires unless someone can suggest where to start.

[mikeexplorer]

4 hours ago, Bxcall1 said:

In better light and with better eyes my son determined that the ignition fuse is blown. He replaced it, which lasted about 30 seconds. Guess I’m chasing wires unless someone can suggest where to start.

Blowing the ignition fuse could be a few things. First unplug the 4WD actuator and try another fuse. If it holds, the actuator got water in the electronics. If it blows again, then you have to trace the harness. Do you have a wiring diagram?

 

[Bxcall1]

Currently I do not. The internet, so far, hasn’t been that helpful in finding a wiring diagram.

thanks for the suggestion 

[davefrombc]

This site offers service  manual  downloads for Arctic Cats.

https://mymowerparts.com/pdf/index.php?d=./Arctic-Cat-ATV-Repair-and-Service-Manuals

[Bxcall1]

Thank you. I’ll check it out 

[mikeexplorer]

Yes that website will have the diagram for your machine. If you want to extract it and make a print of it, one sheet is useless, it will be too small to see anything. Follow my guide I wrote up years ago here. I printed the wiring diagram on 6 sheets (3 across, 2 down) 

https://www.arcticchat.com/threads/extract-and-print-schematics.313549/?post_id=2615590#post-2615590

 

 

[mikeexplorer]

6 hours ago, davefrombc said:

This site offers service  manual  downloads for Arctic Cats.

https://mymowerparts.com/pdf/index.php?d=./Arctic-Cat-ATV-Repair-and-Service-Manuals

Good, that site still exists. The wiring diagrams is the large file, 6th down. The quality of the PDF is very good.

 

[Bxcall1]

Thank you mikeexplorer. This information is helpful.

[mikeexplorer]

15 hours ago, Bxcall1 said:

Thank you mikeexplorer. This information is helpful.

Here is the diagram exported as a JPG. If you look at the orange wire coming off the IGN fuse, it splits off, so if you follow it it connects to the 4WD actuator, Front ACC plug, Neutral relay, foot brake switch, gauge pod, left handlebar controls including a small switch for the hand brake. Your front accessory plus is probably under the pod by the steering, it is a 2 pin connector, commonly used to add grip heaters and winch controls. 

I would disconnect all these things, put a new fuse in, start plugging stuff back in and wiggle each. If the fuse blows before this, then it is a harness issue, probably at that splice. (common issue with 200X Cats) If it holds then plugging in one item at a time should find it. (fuse will blow again) 

 

[Bxcall1]

It looks like it was the wires going to the “dash” lights, indicating N,R, temp, etc. each of them had lost significant wire coating, especially at the ends. After shrink wrap and a lot of liquid tape it’s been running without issue.

[mikeexplorer]

3 hours ago, Bxcall1 said:

It looks like it was the wires going to the “dash” lights, indicating N,R, temp, etc. each of them had lost significant wire coating, especially at the ends. After shrink wrap and a lot of liquid tape it’s been running without issue.

Common issue since the harness moves as you turn the handlebars.  In the re-design of the Alterra the pod is now part of the front plastics and not attached to the handlebars. 

Next time you have plastics off, check the harness for rubbing spots. I use spiral wrap to protect it at potential rub areas.

Thanks for reporting back on your situation.