my 07 must be different than yours,didn't see any numbers on the ecu,4 different brown wires,didn't what to cut so put it back together and will do it the readymixer169 way but I'll just disable it as my adc is wore out due to snowplowing in 4wd for a few years now... I don't think I will ever buy a polaris again,too many things that are of poor quality for the money...

 

Heat shrink butt splice is a good idea, but for a connection like that, I think I would have soldered/heat shrink tubed it, butt splice is still only a compression fit, and has the possibility of loosening over time,or the wires can tarnish in a butt splice, no matter how good you seal it up. Solder is pretty much a bond down to the metal surface, and will hold up better over the long run. I also like the clean look of a heat shrink junction over a big 'ol butt splice anyway !! And as stated above, try and put the "cut" section as far away from sources of corrosion/shorting as possible (read water/mud etc).Just my opinon, having seen so many wiring connections under the hood of cars and trucks go to pot, the more exposed wiring in an ATV would be even more critical.

 

The butt splices that I use for all my connections seal up when heated. They have more or less a coating of glue on the inside and when heated they shrink up around the wires and the glue/sealant oozes out the end and dries quickly creating a water tight joint. Never had a electrical joint get wet or come apart, even on marine equipment using these types. They are a little harder to find and cost a bit more but well worth the extra money.

 

Yup, Im an electrical technician and use them also, but if I can, I like to use solder, just more solid to bond the wires instead of crimp them, just my opinion.

 

Great info on the switch install! I found your post while searching for ADC problems. I have an 07 Sportsman 500 with ADC and when the ADC engages there is a lot of clunking/grinding noise at the front hub. This machine accidentally rolled into a pond (it wasn't running) and was totally submerged. I flushed all fluids three times to make sure all moisture was removed. Any idea what causes this problem? I'm going to check power and ground going to the ADC coil first. If i get this fixed I may do your switch install .

 

If I completely disable the ADC do I drain the fluid from the ADC reservoir as well as the ADC? Or do I have to keep changing that fluid. Thanks.

 

Things were simplified when Polaris went to a common diff fluid for the adc and front diff.You can disconnect the adc wiring,plug off the resevoir function,but not guarantee that the clutch packs still won't grab every now and then. Don't know if your wiring is the same as this one.
ADC Coil wire colors
BN/RD (From ECU pin #11 controls the grounding of the ADC hub coil for operation.)
GY (From AWD switch 12Vdc power is present at the ADC hub coil)