Thanks cornbread2 for that post but it was a day too late! I took it apart and wish i never! I lost the ballbearing for the light aaaaaaah fu*k!!!!!!. Ain't it just my luck the kill switch was fine. I guess it wouldn't be as bad if I could have taken it right off the handle bars but i didn't want to screw up my hand warmers (break some of the heat coils).

 

Ya I took mine apart to but manage to get it back together. I ordered a new part but still wouldn't mind knowing how to bypass it all together in case it leaves me stranded again. The ball bearing almost got me too. Almost lost it.
I won't need the old ball bearing Rubberknob. So if you are strapped and can't find one let me know and I will mail you my spare.

 

ive had my quad apart many times for modifications. ive learned that if your vdo is not hooked up the vehical wont run or start in most polaris quads. so you said your tack isnt working! is it on the same system? does the tack work when you are able to start it? you should get in there with a VDOM and start with the batt and work your way up. also chech for no reading ofl on the vdom display, that will indicate you have a mechanical problem meaning a solonoid or relay is bad. chech your vod for proper opperation by testing it for resistance as well as you kill switch. all these will get you in the right direction. dont wast $ throwing parts at it though. you could even bring it down to the shop and see if theyll diagnose the prob for you and you fix it later.

good luck
ryryviper

 

(ryryviper) I have checked my kill switch and it is fine, and cannot test start it as since the vdo doesn't light up I can't start it. My tach hasen't worked for awhile now and the wheeler started fine. It's now that the vdo won't light up I cannot start it. Sometimes the vdo will light up and it'll start/run fine, until either the vdo turns off and the engine stalls, or you turn it off. Do you know what the VDO wires run through? (stator/ecm/cdi/fuseable link(can't find one on my wheeler)) before they get to the vdo.

 

Im not to familiar with your quad so ill go down to the shop in the mornin and get a wireing diagram for ya and send it to you. mine goes to the ecm but yours could be setup different. I know theres a lot of wires in there and there all protected with a sheathing of some type. its a pain ive been there. but dont worry well get it runnin. try and get a factory service manual. the wireing diagrams will help. but ill look into it in the mornin. oh ya know what, i bet you have a bad ground. if its an intermitant problem i would place my $ on that. when you are able to start it up and its runnin, she diess cause of the vibration of the vehical and the bad ground occures. set your vdom on connectivity and place one leed on the batt negative and the other on every conection in the connector in the vdo. hey its a theary. ill get back to you tomarow night after i get the diagram. latter

ryryviper

 

hey i just looked on EBAY there isnt a shop manual for your quad but there is for the sportsman 500. its like $30 check it out cause the wireing diagram should be the same if not close. ill ask the shop and get back to you. can you bring it to the shop and have them figure it out for close to nothin and then you fix it? that would be easier. ive had to do it in the past. ill keep looking. you got me on a role now. i want to find out jus as bad as you lol.
ryryviper

 

Thanks alot for all your help. I will order a service manual from polaris. As for getting it down to the shop will be hard. It won't start so I need to get some friends out and lift it into the back of a pick-up. Thats why I'm trying to fix it my self. It used to work after letting it sit for an hour or so, but now it's been sitting for like 5 days and no luck! Thanks again!!

 

no need for your buddys. take a strap and run it from side to side in the front of the box on your truck hook the winch up to it since it should be able to work and winch it up. it sould work anyways

 

I have no accessory power at all. So the winch won't work. I've been thinking of wiring an extra battery to the winch if needed.

 

yeah man Ide just bring it to the shop and get er looked at. got a car? jumper cables/engine running and winch it up. you go thet right idea