polaris sportsman 500 (2000) start switch fix/baby spider kill!!!

[@Papajenks]

Is nobody going to acknowledge the spider/fire and screaming around minute 5?😂 Great video though, very helpful!

[@davidhatzenbuhler6888]

I used the 2002 & later key switch with a 2002 & later handlebar switch. No moving the choke and it looks factory. I didn't even have to extend the START wires because I cut them off flush with the handlebar switch plugs. Both ignition keys use an unsealed Metripack 280 plug. The newer OFF-ON_START key-switch uses PN 12092254 shell ($1.09) with 12034046 terminals ($0.25 x 2). I wouldn't use RTV on the switch plugs. They aren't engineered to be sealed. Any water that gets past the RTV will stay inside and corrode the connectors away from any air rather than drying off as you ride. START wires to the handlebar switch are on both of the unsealed Metripack 150 plugs. Postion F on the keyed plug and Position C on the UN-Keyed plug. These wires can be pulled into the pod through a crossed slit in the handlebar wire cover inside the pod and they more than reach the ignition key switch position. I covered mine with expanding mesh sleeve back through the slit to protect them from the sharp steel braces in the pod. These wires are terminated with the brandy new Metripack 280 terminals and inserted in positions A & B of the new plug. For some odd reason position F is next to the connector key. If you're careful you can use the $35.00 DelCity 990174 crimp tool or the equivalents you can find on Amazon etc. The four position switch plug uses the same terminals as the six position plug so you can extract them from the old plug with a 12094429 tool or homemade equivalent and re-install in the proper positions of the new plug. Make sure the retention tang clicks. You can lift it 1-2mm CAREFULLY with a razor blade knife if it's folded too far down to click into place. If you break off the tang it's a PITA to install a new terminal on wire pairs so do be careful. Download the 2000-2001 wiring diagrams. RED and RED/BLACK are shorted when the switch is ON and BLACK and BROWN are shorted when the switch is OFF. Ohm out both switches. On the 4 position switch A & D should be shorted when the key is twisted to ON and B & C when it's OFF. On the 6 position switch C & F should be shorted in the ON position and D & E should be shorted in the OFF position. YMMV. The six Ps of engineering say you should Ohm em out to be sure before you start moving wires from the 4 to the 6 position connector.

[@holeshot888]

good info david

[@MichaelEd]

Great idea on waterproofing electrical connections.

[@holeshot888]

thanks man.. yea its essential and it works.

[@whydahell3816]

Which wires control the kill switch and how to bypass, so the push button works?

[@harveyhudspeth6824]

I have this issue on a 02 scrambler 500 , ordered the new switch without realizing no up start ! I’ve asked if this could be done on the forums with no replies , where do these wires go that you’ve interrupted for switch ? Mine won’t stop cranking if key is on and switch in the on position , I got that you had constant power to one side of switch , and red/white wire in other , did you split the red white ? And tape off one end ? Is the red/ white coming from on off switch ?

[@404Offroad_NotFound]

😂😂awesome 🔥 🕷

[@joeyponthieu4794]

My green light won’t always come on therefore it will not start what can I do to try and fix this

[@whydahell3816]

yeah I still have no fire. new coil, new trigger/pulse coil, new ignition coil, new voltage regulator, new reverse regulator, bypassed only 2 bolt on fuse types I've found. new key switch. only thing not new is kill/start switch that I've torn down cleaned and put back together. no fire. I'm so sad 😔

[@whydahell3816]

also I have spark from CDI box from the blue wire. I unplugged the kill/start switch and found hot wire to jump and turn engine over but still have no spark to the plug. sad again. it's horrible. hate it man

[@gregarnold7989]

I have 2005 polaris sportsman i acidently got solenoid to hot tryin to cross it to start it it melted bought new solenoid now have no power to cluster any ideas??

[@dwayneboz9448]

greg arnold did you figure it out

[@micflynn1]

They used them switches n 325 trail boss and other including 250 2 stroke trail blazer and others. I think it's a bad design

[@whydahell3816]

red and red / white.

[@whydahell3816]

also I have spark from CDI box from the blue wire. I unplugged the kill/start switch and found hot wire to jump and turn engine over but still have no spark to the plug. sad again. it's horrible. hate it man