Fourth/last pictureThe large black connector on the right of the picture connects to the Handlebar Harness.
- Any wire that feeds to the handlebars goes through this connector.
- The Handlebar Harness goes from this connector to the two handlebar connectors located on the center of the handlebar.
- This length of harness goes through constant twisting from turning the handlebars.The two grey connectors in the center of the picture are obviously the headlights.
- The only common problem I see with those is one or more terminals work loose from the socket.
- A simple visual check while lightly/reasonably tugging on the wires is priceless.The black connector on the left of the picture is the Right Hand portion of the Handlebar Harness that attaches to the center of the handlebar.
- This is the connector that feeds everything on the right hand side of the handlebar.
- This is also a handy connector to unplug to eliminate any possible problem from the Kill Switch.
- The Kill Switch from a Gen1 REV is one of the most common failure points, hence the old style that resurged in newer sled.
- So don't be too quick to put the Gen1 style back on your sled. The Grip and Thumb warmers are the most common for electrical issues.
- The Grip warmers are at least twice as likely a problem than the Thumb, but the Thumb is still high on the list. Control Block
- This is the main controls on the left hand side of the handlebar.
- The Hi/Low beam and Start/RER buttons are two possible problems. In competition for the most common electrical problems:
- In no particular order
2. Kill Switch;
3. Start/RER switch;
4. Hi/Low beam switch;
5. Grip/Thumb warmers;
6. Rear/Brake light harness that follows along the seat.
7. Headlight and grip/thumb terminals popping out of their connectors;
I will probably need to amend the list as this is off the top of my head from what comes to mind at this instant. The reason I mention everything in this reply is to give you some hints into re-wiring or restructuring the handlebar harness.
- I have a new thread going for Throttle fatigue
- I need to look into the throttle of the G4 to see if it fits, because it is designed to flip forward as a finger trigger.
- The Kill Switch and Throttle Block are currently the two things I really want to change.
- The two possible switch/connection problems on the Control Block are easy enough to clean, and reliable enough for my liking.