Howdy,

Hoping someone can shed some light on this conundrum. Bought the wheeler last summer and knew the speedo was broken. Later realized the AWD did not work, along with the indicator lights at the bottom of the pod, and the high beam headlight.

Finally saved up and bought a new speedo. Installed same- nothing. Found a schematic and began tracing. Found a broken ground wire below the pod; fixed that and wahoo! had working speedo, working high beam, and working indicator lights. Only problem is, the ATV would not start after the fix!

checked fuel, replaced spark plug, and tested spark with the old plug grounded to the block. When I turned the key, there was ONE little spark, then nothing.

Un-hooked the speedo and the ATV fires right up and runs normally.

What gives? Anyone have a clue? I am at a loss what to do next to fix this darn thing.... Appreciate any assistance!!!! John

 

Sounds like you still have a wiring short problem,hooking up the new speedo could be grounding out some functions.Have had that happen before too,but we were usually able to trace back to the wiring problem causing it.Even the speedo harness connector could be the cause in itself.Unhooked it isn't shorting,hooked up it does.Check this connector/pins out along with retracing your steps under the pod as this is the most common places for shorts. Either at the high beam connector,ignition switch wiring, emergency on/off control switch wiring, or the main harness wiring itself that wraps around from the driver side of the frame. This area receives all the twisting and turning and wear on wiring and connectors.You may have to dig deeper into the wiring loom as you inspect the wiring.A good wiring schematic can help.If you don't have a manual here's one for 5 bucks that can help.2002 Polaris Sportsman 500 Service Manual PDF Download

 

that makes more sense than anything. Must have another broken wire in there somewhere or possible something wired wrong, even. I will do more tracing. Very much appreciate the advice, OPT!