I bought the reverse override/headlight mod kit on ebay and did a search on here as well. I have a 96 sp500 and was trying to do the reverse override mod but
I can not find the gray/orange wire anywhere on my sp. Does anyone know how the heck I can do this mod otherwise? what does the gray/orange wire go to? Just thouhgt you guys could help me. I tried to get help from the guy I bought it from but when I questioned him about this gray/orange wire he wrote me back saying hook the item up to the green and yellow wires, meaning the head light mod witch I already did and works fine.

Bill

 

Don't quote me, but I think the orange/white wire is the key on power lead on the newer sportsmans. I found it on my 2006 when I hooked up my winch, but couldnt find it on my 2004 when I hooked up my thumb warmer kit when it called for it. On the 2004 I just found a key on power wire, I think it was red.??

Sorry I cant be more help.

 

Trailbound was right, That wire is the protected power on lead. I just mounted my horn the other day and I found it. by all means, use it!!

 

in the instructions it says cut the purple and tape ends.Cut the gray/orange wire and tape ends. cut the gray/white and tape the end that goes to the switch and then splice the other end to any red white keyed ign. wire. are you guys saying the gray orange is actually orange white?It does not make any sense to cut a wire that goes to the key but if someone says they have done it then I might try it.[img]i/expressions/face-icon-small-happy.gif[/img]

 

OK, Here is the way that worked great. I took the gray wire cut it mid loom. installed a female steak on terminal and attached it to the terminal strip with the red/white wire in electronics compartment. Installed a male connector on the side that goes to the switch so when I sell this I can just hook up the reverse overide again so no one can sue me.
disconnected the purple wire from the strip on purple terminals in elec compartment. left the green wire intact. It worked flawlessly. The only way I knew this would work was from looking at a wiring diagram I found on the net. Hope this helps all you other guys out too.

 

This kit sold on ebay works on the 800 EFi, It fits all Polaris sportsman's and takes 5 minutes to install, no cutting of factory wires. Item cost $5.99 And worked great on my atv adn has been on for 3 years. reverse bypasses available also.

http://stores.ebay.com/Mountai...subZ245007018QQfrsrcZ1

 

The kit from quadovator.com doesn't require any cutting of wires. It's the one I use.

 

dont know about the headlight one, but you DO NOT have to cut any wires for the override switch. i just used 2 blue wire splicers(not sure the proper name) and added them to the wires in the harness going to the switch.