Polaris Sportsman 400 Electrical Components Wiring Guide

[@NEERD911]

Man you came in clutch, I just picked up the same machine for $400 and it’s a basket case as far as electrical goes but this definitely points me in the right direction. Thanks a lot!

[@erickfunk2557]

Thanks for watching. Mine was a basket case and I slowly transformed it back to what it should be. I figured I’d share some videos along the way.

[@boondocksoverlandandoutdoors]

Thanks man! Awesome video! Very informative! Pretty much answered all my questions! I have exact 4wheeler, out of nowhere it started running very rough erratically…like it bogs down and then all of sudden gets full power ordered a CDI box in hopes of fixing my issues

[@erickfunk2557]

Thanks for watching! If you still have problems after replacing it, go on the Polaris ATV Forums. Their pretty awesome! www.polarisatvforums.com/

[@whatsnextgarage]

Rock solid! Exactly what I needed to see! Well done Erick!

[@erickfunk2557]

Your welcome! Thanks for watching!

[@erickfunk2557]

That would be too easy, lol. Thanks for watching

[@reefshark76]

Top notch electrical break down. Thanks for sharing that!

[@erickfunk2557]

Your welcome. Thanks for watching.

[@benjamingower8678]

@@erickfunk2557zCzxcc

[@scottmay402]

Incredible video well done

[@erickfunk2557]

Thanks for watching!

[@paulvillano8625]

This was super helpful

[@erickfunk2557]

Glad it was helpful. Thanks for helping.

[@ThatBoyMoon]

Can u show me the color codes or which wire plugs in to were for the indicator dash like the temp neutral hi beam reverse and oil temp...jus bought one and non of them were plugged in

[@erickfunk2557]

I would ask your question on the Polaris forums as I don’t have the schematics for it. www.polarisatvforums.com

[@jenrizar660]

Amazing video brother soooo helpful appreciate it

[@ScottFrank-h5j]

Hey I've got a 1996 Polaris L headlights unhooked where does it hook at on circuit board, thank you

[@ScottFrank-h5j]

400 L

[@erickfunk2557]

Hi Scott, I’m not sure where it gets connected on the main board. Try this group as they are very knowledgeable. www.polarisatvforums.com/

[@NoviceCreations78]

Hey bud , I have a Polaris xplorer 400( not sure what year but I'm thinking it's probably around 94 to 98) . I can't get any sparks at all and it looks to me like the previous owner played around with wiring and I just dont have a clue if the wires are where they should be connected. Any help would be greatly appreciated

[@erickfunk2557]

Hello, I’m not certain what the connected wires should be to the main circuit. I would ask your question at the following forum. These guys are very knowledgeable. www.polarisatvforums.com/

[@terrygarcia6356]

Thank you i needed to know about the fuses

[@erickfunk2557]

You’re welcome. Thanks for watching.

[@jesusharo9372]

Can you help me on the waring the sensor from the radiator who ever have this machine cut them off and I don't know were to plug them thanks

[@erickfunk2557]

Hi Jesus, thanks for watching. Please ask your question on the below website. They are very knowledgeable and should be able to assist. www.polarisatvforums.com

[@Trucksfourwehelersthreewheeler]

I have a 2001 Polaris xplorer 400 4x4 and the lights quite on me is there a fuse box?

[@joehann699]

Hello, I have a 96 Polaris Sportsman 400. I've been looking for a new dash or at least the cover for the dash lights, any ideas?

[@erickfunk2557]

Thanks for watching! The cover for dash lights is next to impossible to find. I used a piece of tape and labeled it with what the lights represent. Ask the crew at Polaris Forums as someone may have something for you. They are pretty awesome! www.polarisatvforums.com/

[@lakenivanova7536]

What the hell is a terminator? My Polaris 400 isnt getting any power whatsoever and I'm thinking it's one of the 20amp fuses but I'm having a hard time figuring out where the fuse behind the battery is supposed to lead to, obviously I know the positive and negative wires connect to the battery terminals but what is the terminator at the opposite end?

[@erickfunk2557]

Hi, please check out the Polaris forum as they will be able to answer your questions. www.polarisatvforums.com/

[@MathewJennings-bn5ry]

So I need your help I have the same one and I have no cluster or power At all but it does start with pull start were should I start to fix

[@erickfunk2557]

Hi Matt, I’m going to have you check with the experts at Polaris ATV Forums. They are very knowledgeable. www.polarisatvforums.com/ Thanks for watching

[@Ezekiel86]

Wait, what? Sorry just a newbie, I bought a 1993 trail boss 350 and it's quite identical to yours, I searched and found out that those on pouches are circuit breakers? Can I really change those with fuses like that? It's only 10 amps though. No lights on panel and start key won't work only works with pull string.

[@erickfunk2557]

If you can buy the exact fuses, that would be a better option. You can ask more detailed questions like on the Polaris forums. www.polarisatvforums.com/ Thanks for watching

[@Ezekiel86]

@erickfunk2557 yep thanks to you somebody over there is helping me already

[@CrayCRussain]

I bought one and the oil float sensors red/white wire is not connected to where everything else is (the panel) Can you please tell me where to plug this wire in?

[@erickfunk2557]

Hello, I’m not sure where that wire gets plugged into but the folks on the Polaris forum are pretty knowledgeable. www.polarisatvforums.com/

[@derrickmoore7627]

Hey my battery wasn't strapped in bounced out ripped the wires out of it and the solenoid can show me or tell me where the wires go onto solenoid and batt thanks

[@ramertv6321]

Hey man, I am fixing an explorer 400 for a friend. I have changed the starter solenoid, ignition, and battery and it still makes 1 loud click when trying to start the bike. Any idea what it could be? Edit I just cleaned all the connections to the battery and starter solenoid now the click sounds louder.

[@erickfunk2557]

I was going to say it could be a dirty connection or the starter. I would ask the crew on this forum I posted. They’re very knowledgeable on this. www.polarisatvforums.com/

[@ramertv6321]

@@erickfunk2557 Thanks for the reply it turned out to be the starter which was wierd. Know my problem is I am getting spark to a spark plug tester but not the plug. Any ideas?

[@scotttabor8180]

Hey Eric! I have a 98' Sport 400, do you know anywhere that I could get a build manual. I got the quad in pieces and want to put it back together!! Appreciate the video

[@erickfunk2557]

Hi Scott, try asking your question on the sportsman forum below. They’re pretty knowledgeable. www.polarisatvforums.com/

[@automotivekid3026]

I want to know out-of the 3 yellow wires what is positive and what is negative

[@erickfunk2557]

Hi Kid, please ask your question on the below Polaris forum. They’re a great bunch of guys and gals that know Polaris atvs inside and out. www.polarisatvforums.com/

[@JakeMMelvin]

How much voltage should be going to the ignition coil from the one wire that connects to the top.

[@erickfunk2557]

Hi Jake, thanks for watching. Please check out the Polaris forums as they have very technical people that can answer your question. www.polarisatvforums.com/

[@shedricwalker906]

Where does the yellow and red wire from the rev regulator plug into

[@erickfunk2557]

Howdy! I’m not sure but the folks on the Polaris forum are knowledgeable and will be able to answer your questions. www.polarisatvforums.com/

[@dscanadianoutdoors3257]

Picked myself up a 94 sportsman 400 and I'm trying to trace a broken brown ground wire, wish me luck lol. No power to dash or switches, solenoid clicks atleast.

[@erickfunk2557]

That’s awesome! They are definitely work horses. If you run into a snag, there’s a Polaris forum too. They are very knowledgeable with all types of wiring questions.

[@dscanadianoutdoors3257]

Hey man do know if there is a ground on the frame next to the oil reservoir? Down by the exhaust header, hard to explain. There looks like a spot but there's nothing hooked there for mine and I'm still having issues with this wiring, sucks lol

[@hankpikuni7024]

I have a Polaris ranger 05 that has a push button switch I cant figure out what it does. Its spliced into the red wire with white stripe on ignition key and other wire direct to positive on battery??? What is it???

[@erickfunk2557]

Hi Pikuni, thanks for watching. Please ask your question on the below website. They are very knowledgeable and should be able to assist. www.polarisatvforums.com

[@co5bass5]

Where does the thermoswitch (on the top of the engine head ) wiring connect to? Mine was broke off when I purchased it used, so I'm trying to hook a new one up.

[@erickfunk2557]

Thanks for watching. Please check out the Polaris forums as they have very technical people that can answer your question. www.polarisatvforums.com/

[@erickfunk2557]

Thanks for watching. Please check out the Polaris forums as they have very technical people that can answer your question. www.polarisatvforums.com/

[@adriangarcia5084]

Hey I have a Polaris 500 HO fan stop working, but I tested directly from the switch fan conector and works, so I did replace the switch fan the one is located on the bottom of the radiator. It didn't work.. I did replace the temperature sensor and didn't work. What else I can do.?

[@erickfunk2557]

Hi Adrian, I’m not sure about your model. I would ask your question on the Polaris forums I post below. www.polarisatvforums.com/

[@williamvollrath1366]

Yo my guy I've got a 96 400 2 stroke what size batter should I use to replace the old one with? The one in it is a car quest battery but doesnt have any volt or amps on it

[@erickfunk2557]

Hello, check out this forum as they have experts who can answer this for you. www.polarisatvforums.com/

[@1269BMXER]

Is brown or green positive for the headlights

[@erickfunk2557]

Hello, I’m not certain but if you put a volt meter on the wires, the one that reads 12 volts is positive.

[@lilmep]

I have a question my 2003 330 trail boss doesn’t charge when you disconnect the ground I’ve replaced this components the ecm stator and alternator but still it doesn’t hold charge

[@erickfunk2557]

Hi Josue, thanks for watching. I don't have any answer but you can navigate to the below Polaris forums for assistance. You can ask your question there. www.polarisatvforums.com/

[@woodyperrin8633]

How many wires are plugins is there on this key switch

[@robertwaubano5058]

Can you show me where the engine ground strap is located

[@erickfunk2557]

I don’t have it apart. Try tracing the wire back. I think it goes to the engine and frame.

[@t.tocsmaillup8685]

Please describe the functions of the individual stator wires. Specifically which the ignition one is? (Color)

[@erickfunk2557]

Hello, I’m not sure of the exact function. Please post your question on the following forum. They’re very knowledgeable and can assist. www.polarisatvforums.com/forums/polaris-sportsman.21/

[@t.tocsmaillup8685]

@@erickfunk2557 awesome thank you sir!

[@pedrofigueroa5904]

Man i can really use your help if u dont mind how can i get in contact with you?

[@erickfunk2557]

Hi Pedro, I’m not electrically inclined. I asked and got answers to my electrical questions on the Polaris forum. www.polarisatvforums.com/

[@citionriver]

I have polaris 2001. When I turn ignition on I don't get any power and it would not start. But if I manually pull starting cord it turns on fine. I checked battery it was swelling. Checked voltage regulator and it gave the same power out as it was in. Replaced that. But still don't get any power with key on. Checked battery and get 12.5 V. Any thoughts how to test what can be broken? Thank you in advance

[@erickfunk2557]

Hey there, thanks for watching. I would ask your question on the Polaris forums, someone should be able to assist. www.polarisatvforums.com

[@pinkie224]

I am trying to order a new ignition switch for this same quad? Could you take a picture of the ignition switch?

[@erickfunk2557]

Hi David, thanks for watching. Go to ebay and search for your year and model quad. This is where I purchased mine.

[@Paypay4u]

I need to know were the ignition plugs into

[@erickfunk2557]

Hi Jessica, I don’t have the plastics off the quad so it’s hard to track it down. Ask your question on the Polaris forum listed below. www.polarisatvforums.com/

[@jonathanhunzie4994]

Do you have the pinout for the terminal board or know where i can find it? Thanks

[@erickfunk2557]

Hi Jonathan, thanks for watching. I don’t have the layout but you may be able to find the information you’re looking for on the following forum. These guys are very responsive. www.polarisatvforums.com/

[@noahprice2577]

So where does the two front lights plung in at

[@erickfunk2557]

Hi Noah, my quad is in storage but you can ask your question your question on the forum I provided. The folks are very educational and responsive. www.polarisatvforums.com

[@rodneygraf6289]

I have the same quad that has no power anywhere and I checked the fuses you showed and still nothing

[@erickfunk2557]

Hi Rodney, I would ask that same question on the Polaris forum. They are pretty good at diagnosing issues. www.polarisatvforums.com/

[@happyjermtek9431]

Funk can do right on thanks bro tight info peace

[@erickfunk2557]

Thanks for watching.

[@matthewrobert2888]

Is there 2 fuse breakers on a 330 magnum do you know by chance because I only see one

[@erickfunk2557]

I'm not sure about the 330. Your best approach would be to search on a forum that supports your model ATV. They usually have multiple people that can assist.

[@SmOoThYwOoDy]

How can you tell if the fuses are good or bad?

[@erickfunk2557]

You need a ohm meter to test them. You can pick one up at any automotive or hardware store.

[@anthonycook6276]

What does those wires go to for the neutral might and reverse

[@erickfunk2557]

Hi Anthony, this forum should be able to help you. www.polarisatvforums.com/

[@michaelpresey2273]

I hate how polaris keeps same motor the same through out years but all thier wires harnesses for each year are complelty different for plugs its very frustrating

[@snickerstorino]

What are those 2 fuses for?

[@erickfunk2557]

wyomings elkoholic - I believe those are inline fuses. If you can’t find the exact one, I’m sure your auto part store should have the same volt and amp one. You would just have to splice them together.

[@snickerstorino]

@@erickfunk2557 thanks, i have the exact same 4 wheeler and i got it all figured out. the fuses were both fine the one looks like it is tied to the lighting and the other seems to be off the main power supply to the ignition system. i just got this in and all the bulbs were blown but the fuse was good

[@tamingthewild19]

Can you go thru where everything plugs into the terminal block

[@erickfunk2557]

Do you need me to take a couple pictures of the terminal block?

[@nathanshipman6913]

@@erickfunk2557 yes if you can that would be great.

[@erickfunk2557]

What’s your email and I’ll forward them to you.

[@donalnmadden5648]

I need a pic.to plrase

[@anthonymata3331]

Erick Funk can you send me a picture my email is [e-mail]

[@brucepattison1430]

I installed new battery and turn on my ignition and power to and any

[@erickfunk2557]

I would start with the fuses and make sure you have a good ground connection. You can test the fuses with a volt meter. Doesn’t have to be an expensive one. Lowes and HD have some along with auto part stores.

[@WayneHughesSr]

AN you show me rectifier wiring

[@erickfunk2557]

Hello, thanks for watching. I’m not sure but ask your question on the Polaris forum below. 0:50 www.polarisatvforums.com/

[@mountainslimb8911]

Those are actually not a fuses, they are 12v 20 amp breakers.

[@erickfunk2557]

Cool, thanks for the information.

[@ianhale4466]

You would be a hero if you could tell me what all the wires go, directly from the engine itself, too

[@erickfunk2557]

Ian Hale your best bet is to go on some Polaris forums. They can either get you the schematics or tell you where the wires go.

[@jakeandrew6147]

This is a Xplorer not a sportsman depending on year model can be different

[@erickfunk2557]

The quad in this video is a Sportsman 400. I'm not sure what you're referring to.

[@jakeandrew6147]

Sportsman are all 4 strokes the only 2 strokes are the Xplorer Xpress and trail boss

[@erickfunk2557]

I'm not an expert but don't believe this is true. The model number on the frame is W948040. That's a Sportsman 400 and every part I purchased for it was based on that model number. I know this because I had to call the dealer for an axle.

[@jakeandrew6147]

The Polaris sportsman’s use the same frame and motor

[@charliecourtneytinyswampli3528]

Looks just like mine which is a sportman400 2 stroke

[@brucepattison1430]

Sorry no power to at all

[@woodyperrin8633]

How many wires run to your ignition in an 89 400 sportsman Polaris

[@erickfunk2557]

I’m not sure about your model. Ask your question on the below forum. The folks are pretty responsive. www.polarisatvforums.com/