Apparently Polaris has made an error with the 2006 500efi. The wire going to one of the sensors under the air breather is too short and causes all kinds of problems. Every person I have spoken to with one of these machines has had this problem. It can be repaired with a new piece of wire that Polaris sells you for about $30. My dealer charged me $100 to install and then thought I should thank him because he saved me money because I did not need a whole new harness. WHAT A JOKE. This is a manufactures error and polaris and the dealers are screwing the owners. Buy it and install it yourself.
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I've had similar problems on my 2006 500 EFI. Can you provide more detail as to how/where to buy, and how to install?

 

if its just a single wire, why couldnt you just cut it to splice in a piece to be long enough?

 

he said it going to the sensors................So this tells me there is more than one wire.................Maybe he ment to say wiring harness.........................Caper...........

 

must be if it was 100. bucks to have a dealer fix it.

 

breezes
What problems?

 

breeze?
any other details?

 

The wire connector to my MAP sensor caused mine to randomly spit and sputter. It would never throw a code so it was really difficult to find the problem. [img]i/expressions/face-icon-small-disgusted.gif[/img]

After the 3rd trip to the dealer, they finally found it when they wiggled the wire to this sensor. (Its located on the top of the engine underneath the gas tank close to the seat. It has 3 wires running to it. ORG, PINK, not sure on the other) They replaced the connector to the sensor and it didn't cut out again....until last weekend. But this time, I knew where the connector was and when I wiggled it, everything was fine again, for a few miles.

This time I pulled the connector off and looked inside the connection to make sure there was any corrosion to cause problems. When I reattached it, the CHECK ENGINE light came on and wouldn't go off.

I took it to my dealer, and they ran the digital wrench software on it. They tried to clear the code but it wouldn't clear. When we tried to remove the connector off the MAP sensor, a wire pulled in two. Evidently the wire broke internally but the insulation was holding it together to where it appeared it was good.

This was really strange since there was no strain on the cable at all. The only thing we can figure is the connector was already defective. Fortunately, they had a couple on order already for another ATV that was experiancing the same problem.

Since I have had this problem, I have notice a few others experiancing the same symptoms. I personally think they have a issue with this connector. If after I replace it this time, it acts up again, I will fix it myself by soldering wires directly to the terminals and use my own automotive type connector.[img]i/expressions/face-icon-small-wink.gif[/img]

 

Mornin Flatulent
Thanks for the info, Yours is an Informative post,,

 

i had the problem also. i got mines in nov05 . when my brother got his in april06 i notice that they had redesign that part of the wireing and connection. He never did had that problem with his, but i guess some of them did, because they had redesign that area again with the late 06's and 07's