It's been about a year since I've posted on here, I need help. Well I still have my '93 Trailboss and over the summer I got a different frame from an older model. The frame I got came from a Polaris Trailblazer without a battery, the only differences between myn and this one is the wiring pannel that myn has, this one doesn't and there is no battery box. I did a kinda stupid thing of sandblasting the frame down and making it perfect and I had it powdercoated gray metallic color before I checked into if it would work or not. I stripped myn down and restored every little piece and transfered them to the new frame, It was all going great untill I ran into wiring it up, this frame does not have the wiring pannel all it has is a little strip with 8 terminals on it.. I would guess grounding. Can I make my stock wiring minus the headlights, handlebar kill switch and the keyswitch work without the pannel? Isn't it basically color matching? I know wiring is very confusing but maybe someone knows what I'm talking about. Thanks, Paul

 

OK the wires coming out of the engine or the mag are:
-Brown/White
-Brown
-Yellow
-Yellow/Red
-White
-Black/Red.
I know the Brown/White, White, and Black/Red go to the CDI, because it plugs in.

Now the tricky part is the rev limiter and the voltage regulator wires.

The top box is the Rectifier/Voltage regulator, the bottom is the Rev Limiter

Rectifier has:
-Red
-Yellow
-Yellow

Limiter has:
-Black
-Yellow/Red
-Green
-White

All I need to know now is what wires to connect!! Thanks, Paul

 

Has anyone with a modded 250 or 400 taken the Rev limiter/Voltage regulator boxes off and just re-wired it somehow directly to the CDI. I'm so confused, I don't think it's ever going to work. I went onto Polaris website and printed out a wiring diagram and the lowest year Trailboss they had was 99?? I printed anyway, I believe 99 was the last year for the 250. The diagram would be great if everything was stock but it's not.