Well it happened again!!! Almost about a year ago I had issues with my atv sputtering and stalling. I brought it in under warranty and after 4 weeks I got my atv back and they said it was the T-BAP harness. Well the past few weeks the atv has been doing the same thing. When I started to try and troubleshoot the problem I found the insulation had rubbed off of two of the wires on just before the connector on the T-BAP sensor. I know there is a lot of vibrations due to its location but this is rediculous. I ordered a new wire harness kit ( $60 CDN ). Any suggestions from preventing this from happening again. I plan on putting heat shrink sleaves on all the conductors and making sure the wires are tie wrapped to the frame.

Cheers
G.A.S.

 

Dealer should have used protective plastic sheathing all the way up to the harness conector and this should have eliminated chaffing. Or if you plan on shrink wrapping should do just as well.

 

Either shrink wrapping or wire loom would be good, or both would be even better

 

Good luck. My riding buddy has the same machine that you have and he has gone through 3 already...even with heatshrink and the whole bit. Needless to say, he is not happy.

 

I'm on 3 in just over a year with 800 miles....each one failed at the solder joint inside the connector at the TbAP. This new harness I put a 3/8 bed of RTV around the point of entry into the connetor and around the wires,down about 2" from the connector (TO ADD SUPORT). This took all the vibrations out of the wires point of entry into the TBAP conector, hopefuly this well help. Time will tell.
I Have E-Mailed Polaris but as you all would know!!!! No reply.....

 

The original replacemnet harness had the plastic sheathing but the wires were still loose inside and the insulation rubbed off and wires shorted together.

 

Been it the shop 4 time same issues. Dealer says leave wires loose for the vibration but he did put them in the 1/4 split plastic protective flex conduit.
I have 2- X2 that one has no problem. The wires are very small gauge and Polaris needs a better connector.
BTW had error code 41, 45, & 46 all due to broken wires.

 

Thats what they did with my lastone. Left them loose in the plastic sleeve. While the wire rubbing together actually rubbed the insulation off and they would short together. Dealer called today and said the new harness is in. I am not sure what I am going to do to prevent this from happening again. Definitely going to put heat shrink over each conductor.

 

Yeah...My 04.5 has had the same problem I have repaired mine too...I found what looks like a pretty good solution on ebay under the polaris parts electrical section for 35 bucks. It's an aftermarket wiring harness that lengthens up the harness and has a new wiring with a new connector..It's all water tight. and looks like its pretty good. The item number is 150359590605 I don't know if I want to buy it or wait till mine breaks again. I don't know if this is a one off or if the guy has more of them.

 

I replaced the sensor once and kept the old one which is good. The next time the wire break I will solder 4 wires directly on the sensor and fill in with non-conductive silicone.