Here is the deal . . .

This past weekend I started at the override button override modification. I now have 4x4 in reverse without pressing the button, but the rev limiter is still working.

On newer models, to disable the rev limiter, there is a grey/orange wire that has to be disconnected. On my 96 Xplorer 400 there is no such puppy.

Anyone know how do disconnect/disable the rev limiter?

 

Locate the reverse limiter and disconect the black wire. I personaly dont like the limiter on 2 strokes because I think they can promote plug fouling when activated in reverse.

 

On my 98SP, there are several black wires that run to the circuit board. The one from the limiter has no rubber insulation on the connector so it is easy to find. Remove it and the limiter is disabled.
Greg

 

Greg,
Where is the circuit board? I don't believe I've ever seen it. Also, even though it's not related to this topic, when a bolt would break on the rear of the sp500, did you find that the bolt was worn any? I removed all 4 last night, and there was zero wear on any of the 4 bolts. I was thinking of replacing them before this coming ride, but I want to know if the bolt breakage you're talking about was accompanied by wear on the bolts. I'm getting a little tongue-tied, but I hope you know what I'm asking. Your help is appreciated.
Waylan

 

Just for clarification, is the rev limiter is that little "black box" directly behind the oil tank under the hood?

 

Walexa,

The circuit board only exists on '98s and older. It was used as a common junction point for the wiring. The newer model have a full wiring harness. The circuit board is located under the hood, right in front of the steering post.

Loyal,

Not sure if the box you are referring to is the limiter. The limiter is up there as well as the voltage regulator. Somebody will know.

DJ

 

Most Polaris voltage regulators that I’m aware of (leaving myself a WIDE out there) are mounted behind the grill in front of the radiator (on water cooled models). They’re up there to catch air and keep cool. This might help in your process of elimination.

 

Walexa,
I haven't every noticed any wear on the bolts. I personally have only broke one. Mike replaced his before I had a chance to look at it. Be sure and use locktite when you put the bolts back in.
Greg

 

Loyal,
I know the shop manual says it is right behind the oil tank, but the ones I have disconnected have been on the opposite side behind the radiator. Your bike may be different though.

Hope this helps.
Greg

 

Sounds like you guys don't like your over-ride switch either. Mine never worked from day 1 so I never had to get around it, but My cousin has a new 2000 325 mag 2x4 and he needs to rid his over-ride. Does anyone know where his limiter box is and which wire\wires to unplug? thanx Polcat