Electrical Problem with Sportsman 500

[Jeff244]

I have a 2001 Polaris Sportsman 500. The AWD does not work properly. Sometimes it will engage, sometimes it won't. After 5 or 6 hours of testing and learning how to read a wiring diagram I finally found the problem. There is a wiring harness that plugs into the back of the speedometer housing. If the AWD isn't working, all I have to do is unplug the harness and plug it back in and it will work, until I shut the ignition off. Then it will only work if I unplug and plug it in again. I can make a connection between the 2 wires in the harness and the AWD will work properly all the time. However, I am wondering if it is safe to do so. If it is, I can rig up a switch that I can turn on to use the AWD and bypass the speedometer housing circuit. I will send a picture of the back of the housing, it is the 6 prong fitting that in the picture. I would just buy a new speedometer but it is around $300.00 from the dealer and $250.00 on ebay.

Thanks,
Jeff

 

[Donegal_TDI]

In the absence of someone who can get to the bottom of the issue, I would say go with the switch(waterproof).
You have tested this?
I take it the handlebar switch also goes to the speedometer, to give AWD indication, and is connected internally to these wires.

I also take it that you will be the only person using the ATV,
and if not, you would need to brief the rider on the new arrangement.

Let us know how it goes, or someone else here may have a fix.
Could be that handlebar switch.

 

[Jeff244]

Donegal_TDI,

Thanks for the response. I have isolated the problem to the speedometer. I have another atv and when I switch speedometers it works fine. I am not very good at understanding wiring diagrams, but from from what I can tell, the 6 wires go to: 1) a bunch of accessories. 2) ignition switch. 3) CDI unit (?). 4) Stator (?). 5) Rear AWD hub coil. 6) Over ride switch.

If I cross wires 2 and 5, everything works fine. Wire 2 is "hot" when the harness is not plugged in and the awd switch is on. When I plug the harness in, no. 2 stays hot if the awd is NOT working, if it is working it is not hot. If I cross no. 2 and no. 5, they are not hot regardless of whether or not the harness is plugged in or not and the awd works. So, I think I will just cross no.2 and no. 5 and I should be set. Sorry if this is confusing, I know it is for me.

Thanks,
Jeff

 

[Donegal_TDI]

Might be advisable to go with a low rating inline fuse and include this from the hot supply to the new switch just in case.

 

[Jeff244]

Donegal_TDI,

Thats a good idea. I just went ahead and connected the #2 and # 5 wires directly and everything seems to be working fine (no switch). I think I will get an inline fuse to put between the 2 wires. I was thinking I will try a 5 amp to start with.


Thanks,
Jeff

 

[kenmac]

I looked on parker yamaha.com. they list several 2001 500 models with a speedometer but, I didn't see 1 like yours. parker usually has good prices

 

[Canfield]

I have a 2001 Polaris Sportsman 500. The AWD does not work properly. Sometimes it will engage, sometimes it won't. After 5 or 6 hours of testing and learning how to read a wiring diagram I finally found the problem. There is a wiring harness that plugs into the back of the speedometer housing. If the AWD isn't working, all I have to do is unplug the harness and plug it back in and it will work, until I shut the ignition off. Then it will only work if I unplug and plug it in again. I can make a connection between the 2 wires in the harness and the AWD will work properly all the time. However, I am wondering if it is safe to do so. If it is, I can rig up a switch that I can turn on to use the AWD and bypass the speedometer housing circuit. I will send a picture of the back of the housing, it is the 6 prong fitting that in the picture. I would just buy a new speedometer but it is around $300.00 from the dealer and $250.00 on ebay.

Thanks,
Jeff

Jeff:
Older Polaris models have a seperate 4wd control module. This module also limits the engine in reverse to prevent the machine from going very fast in reverse. It is connected to the override button. When that button is depresssed you get full power in reverse. It also needs to be pressed for 4wd to work in reverse. Starting in 1999 Polaris moved that module to the electronic speedo. If the module portion of the speedo burns out you will loose 4wd and the reverse safety feature. There are several "fixes" on the internet but I would caution you that any bypass will defeat the safety feature on the machine. The 6 prong connector on the speedo is indeed the 4WD portion and the other connector is the speedo signal. Again your bypass will probably work but the overspeed in reverse will be a hazard to someone that is not familiar with the machine and open you up to liability. Without the overspeed portion that machine will go just as fast in reverse as it will in high forward!!!!
It appears as though the module off a pre 99 may be adapted quite easily and the speedo eliminated. That module costs in the neighgorhood of $120.00 The reverse overspeed would then be restored. If you don't feel like making that adaptation then you best off to just pony up and buy a new speedo.