2002 ranger 500 4x4 stopped running and wouldn't restart. Service manual wiring diagram helped identify the hub safety switch as the culprit. Using jumper wires to bypass switch allowed the engine to start and run normally. Inspection of switch showed melted epoxy and a strong smell of burnt electrical. Unable to find replacement part either used or new. Is there a work around other than jumper wiring?
I would like to install a water to air cab heater in my 2500 but cannot see how to tap into the cooling system so the heater will have flow from the engine water pump except when the thermostat is open. Does anybody know if the factory heater has some kind of thermostat adapter that lets hot water circulate through the engine and the cab heater core before the thermostat opens? Unless I can solve this water flow problem it seem pointless to install a cab heater if it will just have intermittent water flow when the thermostat is open.
I did buy a $66 Mr. Heater MH4GC Golf Cart Propane Heater on Amazon but it is really hard to find a place to install it that will be convenient when two or especially three people are in the seat. Decided it was too much a fire hazard because it would be too close to the riders and if there was a gasoline leak it would likely ignite the fumes. Also it didn't really put out much heat. So I returned it.
The only other idea I had was doing something with an exhaust heat air to air system like the Volkswagon Bugs were in the 60's but this has many challenges too.
If I could just figure out a suitable water flow path I would be good to go. I do know where there is a Mule 2500 with a factory heater but I won't be back that way to see it 650 miles away until next summer. If anybody has one and could post some photos of the heater water connections to the engine, that would be wonderful.
Many thanks, Mike
Well, after a bad experience with repairs to our Trooper, Lloyd tore into the engine himself. We originally wanted to save time by hiring the engine rebuild out, but that bit us square in the butt. Remember the discussion about Silverbullet motorsports in Yuma??
Stay tuned....we'll let you know what happens.
Has anyone rebuilt the engine in these troopers?
Does anybody know if a kawasaki FD440V engine will interchange with an FD620D? It looks like the same engine from the outside but has an internal governer which you would not need to connect and a different crank output side so maybe you could swap cranks or have the FD440V splined at a machine shop. It is 15HP instead of 20 HP which isn't great but is probably plenty of power for most applications, so I am assuming it has a different bore size but you can pick them up for cheap. I don't need an engine now but would like to have a spare on the shelf. The FD440V is used in John Deere rider mowers model LX178.
Here is an example of one on Ebay with decent pics:
Polaris RZR Ranger 800 Engine Rebuild Service S crew 4 Xp Motor 700 On Ebay