1998 Polaris Sportsman Won't shut off! Wiring diagram simplified!

[@jonflin5801]

Thanks brother

[@nninmann]

was having similar issue...starter was turning but no spark. then pulled the black wire that runs to CDI and it fired right up...but no ability to shut off with kill or key. had to reconnect CDI black. This morning i was testing some of the other black wires and now I get nothing. no power anywhere just minutes after it was running. kill is bad? or key is bad? stumped

[@TitaniummanGarage]

That or the cdi is bad. One of the 3.

[@nninmann]

Major issue left to solve….appears stuck in AWD and not able to turn it off…

[@MiaGranlund]

Sometime i have that problem, not shut of by key or switch, can u figure out which ground i should check? ( -97 500 )?

[@TitaniummanGarage]

Here is what I do. I add a ground from off of the coil. All the ground wires go there and get corroded.

[@BruceHugHs-ou6cg]

Where did the wires plug into on the on the board

[@kalegiles8924]

So I have a question, the original cdi i box went bad on my 97 sportsman 500. I replaced it with a couple of after market ones and it wouldn’t start, like it wanted to but wouldn’t. So I pull started it,fired right up and ran like a top. So I thought that’s weird, so I just happens to just push the green starter button while it was running and it immediately killed it. Now on the original cdi box it never did that. And even with a brand new oem cdi box it still kills it when i bump the green button . I’m at a loss here. Can you please help me out😂

[@TitaniummanGarage]

You might have a bad run/ stop/kill switch. I've seen them get crusty on the inside.

[@kalegiles8924]

Thanks for getting back to me, I have checked that and it is really clean inside. In fact I do believe it was replaced a couple years ago to see if that was the issue. I’m wondering if there is something in that electrical board that has shorted out or making a bad connection

[@TitaniummanGarage]

@@kalegiles8924 I've had it happen once. Check all your contacts on the board and make sure you have a good ground.

[@kalegiles8924]

Thanks for you help. I may end doing what you did. Just re route all the ground to the frame to ensure a good ground

[@codyhenderson9356]

Question!?? I have a 99 Polaris sportsman 500 that has clicking from the breaker under the seat when key switch is turned to off position and the breaker in the front of the four wheeler has no power going to it. I'm at a loss please help

[@TitaniummanGarage]

The breaker or the starter solenoid? The solenoid clicks when you start it. I would check all the wires going to it. I had 3 with broke wires and no power. I spliced in a good wire...had power.

[@codyhenderson9356]

No it's not the starter solenoid. It is relay beside it. 20 amp by 12 volt.

[@codyhenderson9356]

Brother I've got the same for and could really use your help. One day I was driving to the backyard and it turned off. The green neutral light would not light up. And I had to unhook the battery because the ignition switch wires were getting extremely hot. And there was a clicking from a relay underneath the seat. I figured there was a short somewhere, so I went through the harness and found a couple possible shorts but they didn't fix the problem.

[@TitaniummanGarage]

If you had or still have a short, you might have blown the neutral light bulb out. I would trace your wires by the handle bars. If the relay was clicking, sounds like something by the start button.

[@dajokerkd]

I need some help what color wires did you hook you key switch to on the polaris and what are the colors on the polaris that goes to start button

[@TitaniummanGarage]

Grey whith the white stripe goes to start button. The red with the black stripe goes to the on switch on the key switch. So power is only to it when the key is on.

[@TitaniummanGarage]

By start button I mean 4x4 button

[@TitaniummanGarage]

Oh sorry I miss read your post. There is another red wire going up to start button and another red coming back.

[@mr.octopus6972]

You just made me find my problem. It's actualy so easy it's almost dumb. Just turn off the key and then force it a little bit 1/64th of a turn. PROBLEM GONE ! I guess I must have gotten a little rough on that poor key and turned it on forcefully so it moved in the hole contacts where not touching properly 😃🤝🤝🤝

[@TitaniummanGarage]

Right on! Yup...sometimes it's the simplest little thing.

[@mr.octopus6972]

​@@TitaniummanGarage Since then I've put hot glue in there. It can't move no more but I will be able to remove it if needed.

[@sheliafleming]

That look just like my 4wheeler but the words were you plug the. Wires up at some are gone don't no were to plug them up at can you send me a few. Pics please

[@sheliafleming]

Can you help me please

[@ls2005019227]

Great video! Chasing down wiring/electrical issues can be such a pain. I've got an '01 500HO, & grounding/voltage regulator/4wd/speedometer seem to be common issues. In fact, I'd be surprised if that speedo isn't fried (i.e., the diode melted out), since it had already got the CDI and stator. Thanks again!

[@TitaniummanGarage]

Thanks. I did screw up the video. On my drawing it was supposed to be Rev Limiter...not Rectifier. oops!

[@andrewfitzgerald9417]

Hey. A little off topic here. I have basically the identical 98 sportsman 500 in green and I broke a rear axle yesterday. The back end of the bike needs work anyways. I do have a complete parts bike but it's a 02 03 sportsman 400. I have the trans and axles and control arms. Everything I would need to do a swap. My question is do you forsee any problems swapping everything from the parts bike to my 98? Thanks. Love the content by the way. It's helped me a few times when I was stumped.

[@jamesmacfadyen92]

Good info.gota clean the crusties.i got a 96 300 explorer.had to replace chains,sprocs,all drive seals.just curious y center,front seals r so expensive 20$ ea.havnt seen u work on a 300 air cooled yet.every one has liq cooled quads.dig the channel👍

[@TitaniummanGarage]

There is a reason I don't work on 300's. A little under powered and the bearings go out on them. I resell what I repair. Not many people want 300's. Its 400 2 stroke or 500's where I live. I try to buy what people want. Plus parts are more expensive on 300's as you are finding out. Thanks for watching.

[@christripptripp797]

All you have to do is disconnect the black wire from the cdi.

[@TitaniummanGarage]

Sometimes that works. And sometimes it won't shut off with the key when you do that.

[@codyhenderson9356]

I wish there was a way other than this that I can contact you and talk to you verbally.. so much context left out

[@lookoutmountaingarockhunte1300]

THANK YOU GRAT JOB

[@sweatingbullets4235]

Essentially all you did was created a new ground bar good thinking if your one ground bar is bad make a new ground bar I like what I see

[@TitaniummanGarage]

Pretty much. These older Polaris have ground issues as the wires get old. 90 percent of my repairs are electrical. The other 10 is carb issues.

[@dorothymarshall6233]

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