i work in light vehicle repair at tallil airbase in iraq. i am very good at wiring and mechanical problems. i build drag and circle track cars in states for a living for the last 11 years. now the problem, i work here as an outside contractor for the military, i came here hopeing to make a difference and help the solders, ive not workd on ATV very much. there are polaris 4x4 and 6x6 all over the base the solders use for transportation, many are torn up and im trying to get them running for them in my spare time. i have one in shop now that was brought to me , the engine has just been changed i think with a newer engine, the solders brought the old engine with it, the old engine had a 7 wire plug for the ignition box and the new engine has a 6 wire plug for ignition, i matched the wire colors on the old ignition witht the new but there is still 1 extra wire, im getting no spark at the plug, i installd a new coil, the engine turns over very good, im looking for a simplified way to bypass all the unneeded wires and make it as simple as possible and still run and charge, there are several boxs under front hood i have no clue what they go to or do, i have an e mail address that diagrams or schematics can be sent to for me, thanks a lot for any help, i know the solders will be very thankfull, not good walking in 130+ degree heat. it is a polaris ranger 6x6 manufacture date is 1-15- 2003

 

Just a guess and trying to keep your post near the top so people can help out. The older 500s didnt have a tach in them I think, but the newer engines do. Is the motor for a ranger, is it a crate motor, or is it out of an ATV? The 2004.5 ATV motors got the new electronics I think. It included the tach. Other than that no other guess. Maby it needs a different ECM that the 2003. there is a full parts diagram for polaris at www.yourwaytofun.com

 

really wish i could help but i cant casue i really dont know much about the wireing on the bikes....trying to keep up ur post to the top so people can help u out

 

the thing is if its a differnt engine(size) or a differnt year the electronics have changed so its hard to tell. my suggestion would be to getthe ser. number off the engine and email a polaris dealer and tell them your story and have them tell you what the engine goes to and the year and maybe they can tell you the differnce. being your over there helping our "great and honored" troops they may give the info directly. the only help i can give is there is a break down of what the parts are in the polaris site if you put the yr and model in. good luck.

 

Good luck and god bless.

 

the numbers off the engines are thr original engine is engine family 2FJXB 498LGA model EH50 and the replacement engine is engine family 6FJXB 498LGA model EH50

 

You can go on bigbuckrack.com and download free the parts manual for the 2003 Ranger. There were significant changes for 2003 models manufactured after 1/07/02 including it appears in the ignition. From the numbers you have provided the new engine appears to be an 06 model hence the 6 first digit. You will need to find an 06 engine electrical diagram if I am right about the engine year and compare it to the 03 parts/diagram from the free download to see if it will help. Unfortunately there is no 06 parts manual download from bigbuckrack.com for the ranger yet. Someone else may know another site that you could get it from. Good luck, stay safe and thank you helping our boys.

 

thanks for the help, ill try to keep the post around the top so it can be seen, ill check the info out now

 

thanks