Information needed on connected a heated throttle cable

[jedi_4_life]

Hi All,

On my max IV the red toggle switch for the heated throttle cable wasn't working, (it had a loose connection and flickered on and off) so I went to radio shack and bought the identical one. I marked which wires went where (there are 3 contacts on the back of the red rocker switch for the heated throttle cable) and disconnected the wires. I had some other work to do on the max so it took me about 1 week to get back to hooking up the new switch. (BTW this "other work" involved removing the engine so I did some major work and hope I didn't mess up any electrical stuff. Once the engine was reinstalled, I snapped the throttle cable and had to jury rig it to work. I'm not sure if that has any effect on my issue.) When I hooked up the new switch it didn't work. I looked underneath to try to see if anything else was disconnected, and I did notice one black wire that was really short that didn't connect to anything. Now I'm really confused because I don't know how it was connected. Here's what I know:

A red wire from the back of the machine went directly to the middle wire on the heated throttle cable switch. A white wire from the back of the machine split (using one of those 3-way plastic crimp splicers), and from there one wire (now red) went to the first lead on the heated throttle cable switch and the other wire (white) appears to go to the hour meter. The 3rd lead from the heated throttle cable switch had a black wire connected to it. This wire was spliced (again with one of those 4 way plastic clamp splicers) and one went to the ignition, one went to the hour meter, and the other one is extremely short and went to nothing.

Does anyone know if this wiring is correct, or does anyone have information on the proper way to connect a heated throttle cable??? Unfortunately I don't have access to the old switch to even see if everything is ok.

Thanks.

[jedi_4_life]

Does anyone out there have a heated throttle cable that they installed that might be able to help me? Thanks!

[George]

Does anyone out there have a heated throttle cable that they installed that might be able to help me? Thanks!

I have a kit waiting to be installed. When I go back (in a few weeks) I can look at the directions...maybe scan and post them.

You might try contacting Hey_Dan on this site. He sold me the kit and works at Recreatives.

[swamp witch]

[QUOTE=jedi_4_life;54665]Hi All,

(using one of those 3-way plastic crimp splicers)(again with one of those 4 way plastic clamp splicers)

I've found the only thing reliable about crimp splicers is they will fail.Anything is better than those things.I'd personally solder the joint and insulate.That you can rely on.If it needs to disconnect,use an inline connector[auto connectors work fine]After working on electrical things all my life I've found most electrical faults are in connections.Could also explain why the light was flickering.

[mark m.]

I agree with swamp witch. I like to solder the connection then put shrink tubing over it.

[jedi_4_life]

OK thanks for the help. I think either the small light in the switch, or a fuse is out. I checked the atv yesterday and the battery was dead. I apparently left the HTC switch on, although I did not realize it since the light on the switch never came on. It was mentioned from RI that the 2 Amp fuse might be blown. Can anyone tell me where that fuse is? I thought it was in the front left area of the dash but when I checked the only fuse that was there (that I could find) was a 30 amp fuse. Any ideas where the 2 amp fuse is...or is it not a 2 amp fuse but something else? Thanks.

[rigidrider]

Their are supposed to be two fuses, one 30 amp and one 3 amp they are right next to each other unless a previous owner removed it.

OK thanks for the help. I think either the small light in the switch, or a fuse is out. I checked the atv yesterday and the battery was dead. I apparently left the HTC switch on, although I did not realize it since the light on the switch never came on. It was mentioned from RI that the 2 Amp fuse might be blown. Can anyone tell me where that fuse is? I thought it was in the front left area of the dash but when I checked the only fuse that was there (that I could find) was a 30 amp fuse. Any ideas where the 2 amp fuse is...or is it not a 2 amp fuse but something else? Thanks.

[swamp witch]

Doudt you fuse is the problem

You said the light was flickering originally.That sounds like a loose connection.If you blew the fuse the circuit would be dead until you replace the fuse.The H.T.C. may have been installed without fuse protection [silly move].Check the switch and the light bulb.Make sure the bulb is tight.

[jedi_4_life]

OK thanks. Here's what I found. There is no 2 or 3 amp fuses nearby...only a 30 amp fuse. The switch for the HTC does work. I took the advice from Dan and watched my amp gauge while I turned on the switch. The gauge did move, indicating that the HTC was functioning. The light on the switch did not work. I tried another switch and also didn't work. Looking at the schematic of the switch, it seems that the 3rd lead is a ground, and that is what causes the light to go on. I checked for continuity with the ground and I did have continuity. Not sure what's going on here. Worst case scenario the switch just doesnt have a light...but I sure would like to have it. Can anyone tell me....if there is a 2 or 3 amp fuse installed and I just can't seem to find it...and if it's broken, would my HTC still work but not the light? Or would the HTC not work?

Also, if I wanted to add a fuse for the HTC, where do I add it? This is not something that I've done before. Thanks again for all the help!

[jedi_4_life]

One more thing. Does anyone know the gauge of wire that is used for the bulk of the wiring in the dash? I'm talking about the wires that go to the hour meter, amp gauge, ignition, heated throttle cable, etc. Thanks!

[swamp witch]

Put the fuse in the wire supplying power to the switch

[locosmith]

problem

the top post on your switch is ground, need it for your light. you already grounded the cable at the engine end thats why it works. 12 gauge will work, the black is the ground color, red on your switch for +, white is + from key switch

[Mike8507]

I dont know a lot about what the max has but usually lighted switches have three connections....one will be the feed , one will be the load (in this case the HTC) and the last one is a ground. If the feed and load are connected the HTC will work however the light on the switch will only work when the last wire is grounded. It sounds to me that your ground wire is not connected.