Corrosion

[szprod]

I have a Polaris 850 XP 2012 with EPS and the EPS stopped working all the sudden after parking it for a month or so after going to Ruby Falls. I ended up pulling off the front cab plastics and I found that the relay for the EPS that's in behind the Fuel Hose had corroded. All Polaris did was plug the relay in then put a couple wraps of electrical tape around the relay and plug to the main wiring harness. Due to the location of the relay and it being taped sideways all the mud that fly's up from the tiers goes onto the relay. I did some searching and this is a very common issue with the Polaris EPS quads. I'm wondering what the best way to fix it is. If I dielectric grease the connection how much do I use? Do I just pack it full? I was also thinking of dielectric greasing the connection then waterproof sealing it with rubber self amalgamating tape. Any suggestions would be appreciated!

 

[TylerG]

They sell an update kit that solders in there, eliminates an exposed relay.

 

[Puba]

I have a Polaris 850 XP 2012 with EPS and the EPS stopped working all the sudden after parking it for a month or so after going to Ruby Falls. I ended up pulling off the front cab plastics and I found that the relay for the EPS that's in behind the Fuel Hose had corroded. All Polaris did was plug the relay in then put a couple wraps of electrical tape around the relay and plug to the main wiring harness. Due to the location of the relay and it being taped sideways all the mud that fly's up from the tiers goes onto the relay. I did some searching and this is a very common issue with the Polaris EPS quads. I'm wondering what the best way to fix it is. If I dielectric grease the connection how much do I use? Do I just pack it full? I was also thinking of dielectric greasing the connection then waterproof sealing it with rubber self amalgamating tape. Any suggestions would be appreciated!

Pack it FULL!

 

[whoDEANie]

What a PITA, that quad is still like brand new. You can't sue too much of the dielectric grease, but the kit TG mentioned probably sounds like the way to go.

 

[TylerG]

What a PITA, that quad is still like brand new. You can't sue too much of the dielectric grease, but the kit TG mentioned probably sounds like the way to go.

on Sara's we had the relay get too corroded in just over a year, at that time Cycle Works West had a "Service Replacement" for the original relay, but we only bought 1. If & when it goes again, I'm going to put the update kit into it. I know Mattmedic put the update kit into Jeepchics this year, and if he can do it, any of us can

I think the update kit runs right in and around $50.

 

[szprod]

Yeah mine has only 800km on it and it was corroded like crazy. Just silly how it's designed when it would be so simple for them to run longer wires and just put it in with the other relays in the fuse box. So the relay is 18.00 and I'm still trying to track down the update kit.

 

[TylerG]

Yeah mine has only 800km on it and it was corroded like crazy. Just silly how it's designed when it would be so simple for them to run longer wires and just put it in with the other relays in the fuse box. So the relay is 18.00 and I'm still trying to track down the update kit.

cycle works west should have it Chad.

 

[AreWeThereYet]

While you are in there, pull the 2 plugs out of your power steering unit and put dielectric grease on them as well, you will have to remove your battery to access them.

 

[szprod]

While you are in there, pull the 2 plugs out of your power steering unit and put dielectric grease on them as well, you will have to remove your battery to access them.

Yeah I found those two plugs already and greased the hell outta them but rather then go from the top I went in from the side and got them off with a struggle so I almost broke a tab off the connector after having to pry on it. I'm sure it will fall off soon because it is white with fatigue so if that happens what does a guy do to secure the connector if there is no tab? I was thinking just do a couple small tacks of glue or JB weld to hold it on and it should give pretty easy if I need the connectors off in the future.

 

[AreWeThereYet]

Yeah I found those two plugs already and greased the hell outta them but rather then go from the top I went in from the side and got them off with a struggle so I almost broke a tab off the connector after having to pry on it. I'm sure it will fall off soon because it is white with fatigue so if that happens what does a guy do to secure the connector if there is no tab? I was thinking just do a couple small tacks of glue or JB weld to hold it on and it should give pretty easy if I need the connectors off in the future.

Silicon, easy to remove and enough to hold when dry

 

[szprod]

I got the new relay installed, cleaned up all existing wiring and cut out all the butt plug connectors then soldered all the wires and heat shrunk them. All the plugs are greased up, quad is ready to see the trails again!