I can repair this easily, but where do i route this through, if it touches the carb will it burn up again?

Also found a short near the bendix leading under the hood to some type of solenoid.

2001 Sportsman 500 HO

Breather line

Partnumber for the electrical wire?

 

To start out with the big black vent house should have been routed behind the frame to keep the exhaust from touching it, routed close to the carb then leading to the air box. The stator harness sheathing looks like rats have been chewing on it or heat from the exhaust has melted part of it. You can repair any damaged wires and install a wire loom and zip tie it.Plus on the brown ground wires to the coil mount,just splice into a good section and remount. I've had to repair much worse than this on several "rat attack" machines farmers have drug in to the shop! You never know what you might find until you start unwrapping it. Just like Christmas presents OPT

 

i found another air line that came from the air filter box, and routed it along side the tube that looks like a pcv valve on the left side of the bike.

I started to tear things apart and i might just splice the wire and start pulling the wire through. Kind of worried of what im going to find in the recoil/starter wiring....

 

yup, opened up the wiring loom on the side, and only that one wire is TOASTED!
The others were in tact, i guess ill just do that one wire.

OPT, where are the fuses located?
I just want to make sure theyre not popped.

 

No fuses on a 2001 just to breaker that self reset. #2(main 20A) and # 3 below(Fan only).

 

Both of these lines are vent lines. One from the upper oil tank that routes to the air box and the other one you can trace down to the engine crank case vent. Any places that that they may rub against or be subject to heat,you can wrap with insulating foil foam sheathing available at any auto store. Just have to have patience and take it one step at a time on the wiring,it's called process of elimination OPT.

 

definitely, getting some wiring, and found a crack on the upper front suspension mount. Welded!