I am new to the board, and have found it very informative.

I have an '01 500 H.O. Sportsman. I recently performed the the reverse override modification which bypasses the reverse speed limiter. Shortly thereafter, I began having problems with no power and bad bogging. It was almost as if the speed limiter had activated itself at all times, in all gears, forward and reverse. I did the normal troubleshooting (fuel, throttle, etc.) and have discovered the following: bike runs like crap until I unplug the lower wiring harness from the reverse override button fixture on the handlebar. The bike then runs great. That is, until I shut it off and restart, and its the same thing all over.

Has anyone else had similiar problems, or have any suggestions?

 

I have done the mod on my 01 Sp500ho, and on my buddies 01 500 Magnum, both have worked flawless

 

FYI....... this is the version I used. Hope it helps.

Someone asked how to do this some time back. I can’t remember if anyone offered a simple solution. Here’s one.

The bypass operation involves cutting one wire and installing one jumper (tying two wires together):

1.Disconnect (cut) the “19 PUR” wire going to the Left Handlebar Switch Assembly “C” terminal. Be sure to properly tape and secure the loose ends. Cutting this wire will remove the engine limiter signal, and prevent the reverse light from coming on as a result of step 2.

2.Jumper the R/W wire to the GRY/W wire. This can be done either at the 1) Left Handlebar Switch connector (terminals “F” and ‘B”), 2) the rear transmission switch connector (terminals “A” and “C”) or 3) at the "“splice blocks". Tying the two wires together at any one of these locations will give the same results. Be careful not to cut the R/W wire because this is the switched “hot” wire from the Key switch. And remember your AWD will depend on this connection.

For drivers not familiar with the circuit details, the system uses two transmission switches to perform the following functions:

1.Turn on the Neutral light,
2.Turn on the reverse light,
3.Send a engine limiter signal to the engine control circuit while in reverse (through the 3-pole Override Switch),
4.Engage the front hubs when in High and Low range.

After the "operation", the Neutral and reverse light will work normally, but the transmission switches and the Override Switch will not be functional with regard to engaging the front hubs (4X4); the 4X4 will be engaged anytime the AWD switch is on.

Expect the AWD light to be on any time the AWD switch is on, even in Neutral.

This information was derived from the wiring diagram of a 2001 HO –it may not apply to all models. I recommend you confirm these details using your own diagram before proceeding.

One advantage of doing the bypass this way (as opposed to installing a separate bypass switch) is that it can be reversed at any time without leaving any noticeable scares.

Good luck.

 

Something has obviously "come off the track" as I have removed the bypass, restoring the original factory wiring, and still have the problem.

 

Hmm, i think all you have to do to bypass the limiter is unhook the (green ....i think can't remeber off the top of my head now...or is it brown) wire that goes from the CDI to the circuit board. I have done this several times...but just for diagnostic purposes