Wiring Harness short causing various electrical problems: not charging, not cooling, etc

[122lake]

For those who are experiencing any one of an array of electrical problems check this first before making any major part replacements. Remove the belt guard and look for a major wire harness running down along the engine (you can see it through the side frame opening just above and ahead of the primary belt drive)

Try lifting the harness and look for a small metal protrusion near the front engine mount bolt. Check to see that this protrusion has not pierced the harness causing a short.

This was why my 08 Nytro RTX (main wire to voltage regulator shorted out) wouldn't charge and killed a battery and why the cooling fan would not run in both my 09 Nytro MTX and my friends 08 Nytro RTR (his had 5 wires burned or shorted out). 3 of 3 machines!!!!

Because this is such a large harness I believe a short here can cause a variety of different issues depending on which wire is impacted.

Repairing the harness is a pain as you need to remove the steering assembly and air box (was able to to get at the air box throttle body clamps without removing the rad - just removing the bolts).

If the metal protrusion didn't pierce the harness yet it will likely happen eventually. Try repositioning any tying the harness up a bit or inserting a spacer between the harness and engine protrusion to prevent a future headache.

 

[radianguy]

Been there had intermittent spark issue.
Seemed like a coil breaking down after sled got hot (warmed up) chased it for a while until I went into the harness and seen where it was rubbing on that engine nub.
Fixed the harness and no issues since.

 

[THEROOKIE]

Have not had issues myself, but seen it come up on TY before. So last year when i removed the subframe to install grizz gusset plates, i cut that exact nub off with a dremel. Good post!

 

[Sevey]

Thanks for the heads up on this. I checked my sled and that nub seemed to be removed but there was some sharp diecast. I wrapped the wire harness with bicycle inner tube to protect it and then zip tied it.

Great post.
Thanks
MS