While finishing up on my alignment for the CATVOS 3" kit last night, where I was starting the rig to drive it around the neighborhood in-between adjustments, I went to turn the machine on one last time and nothing. No dash, no lights, no solenoid/relay clicks, just dead. I knew I hadn't touched anything electrical on this machine, so it wasn't anything I had done.
Started playing around and finally found the culprit under the hood. Where the main 50 AMP fuse is bolted down in the fuse box, the dip-Sh*t that built this part on my rig had over tightened or cross threaded the bolt into the nut insert and it had stripped so the fuse was loose in the holder. After I removed the bolt, you could see that hardly any threads were left in the threaded nut-insert. So I got extremely aggravated as I had planned to ride tomorrow afternoon after not being able to at all since the weekend I bought it in January, threw a few tools around the garage while I was at it. But this meant that a trip to the dealership was out of the question. So I removed the fuse box and opened the little tab underneath where you can get to the clips that hold the nut inserts. Removed them, and saw that they were square, not regular nuts. I panicked a but thinking there was now way to find them anywhere.
Luckily Lowes had just what I needed. 5mm botls with 0.8 thread count. Got 4 bolts, nuts, lock washers, and flat washers because when I removed the bolts that were not stripped, all of them still had some of the metal material from the nut insert stuck in the threads, so I only assume it is a matter of time before they all fail. the 5mm nuts also fit in the square hole on the fuse block perfectly, so it turned out to be an easy fix.
However, I mention all this because I can't imagine what I would do if this happened out on the trail and my machine power cut in and out as it went over each bump in the road. So check your main power fuses! if its tight, leave it alone, if you can jiggle it even a little, better look into replacing the bolts and nut inserts. Honda used dinky stainless-style soft metal bolts and nuts on these things, makes me think about all the other potential issues it could have later.
In all honesty, I was missing my RZR last night. Never had to turn a wrench on her and I hate even thinking that.
Started playing around and finally found the culprit under the hood. Where the main 50 AMP fuse is bolted down in the fuse box, the dip-Sh*t that built this part on my rig had over tightened or cross threaded the bolt into the nut insert and it had stripped so the fuse was loose in the holder. After I removed the bolt, you could see that hardly any threads were left in the threaded nut-insert. So I got extremely aggravated as I had planned to ride tomorrow afternoon after not being able to at all since the weekend I bought it in January, threw a few tools around the garage while I was at it. But this meant that a trip to the dealership was out of the question. So I removed the fuse box and opened the little tab underneath where you can get to the clips that hold the nut inserts. Removed them, and saw that they were square, not regular nuts. I panicked a but thinking there was now way to find them anywhere.
Luckily Lowes had just what I needed. 5mm botls with 0.8 thread count. Got 4 bolts, nuts, lock washers, and flat washers because when I removed the bolts that were not stripped, all of them still had some of the metal material from the nut insert stuck in the threads, so I only assume it is a matter of time before they all fail. the 5mm nuts also fit in the square hole on the fuse block perfectly, so it turned out to be an easy fix.
However, I mention all this because I can't imagine what I would do if this happened out on the trail and my machine power cut in and out as it went over each bump in the road. So check your main power fuses! if its tight, leave it alone, if you can jiggle it even a little, better look into replacing the bolts and nut inserts. Honda used dinky stainless-style soft metal bolts and nuts on these things, makes me think about all the other potential issues it could have later.
In all honesty, I was missing my RZR last night. Never had to turn a wrench on her and I hate even thinking that.
