I have a Polaris 4x4 300 1995

I am looking for the service manual, but cant find it anywhere. I did try the sticky but that link 404'd on me. I need the wiring diagram so I can replace the tail light (it didn't come with one) and I am going to use some of those LED strips.

I also can not figure out what is up with my starter solenoid. are they all the same kind of 12v solenoid. when I got the machine, the solenoid was smashed, so I replaced it with one I had (possibly from a lawn tractor) but it does nothing when I hook up the jump pack and attempt to start it, the only thing that happens is when I turn the key, the fan of death turns on (those of you that know this model know what i mean when I say fan of death)

 

Red/White and Orange,plus Brown(ground) wires for the tail light.The reason the fan is on is probably the sensor has shorted out/broken on the rear motor mount or someone has tied the two wires together.This was a common problem.You need the correct solenoid if the one you have doesn't have the small wire leading to the ignition switch. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
The starter is at the bottom of the engine and the gear shaft(bendix) is behind the recoil.

 

I used a solenoid similar to this: http://www.randysenginerepair.biz/catalog/$(KGrHqF,!hkE2fLwgLpUBN)d)JhL-!~~0_1_9044_1.JPG

which of the 2 rear light wires do what (aside from the ground)
Is one running lights, and one for brakes?

can i get some more info on the fan wires. and I did notice something broken by the carb, round plastic piece 2 wires attached to it. and 2 contacts showing where it broke, cant find where it broke from. I will snap a pic when I go out to the garage later.

 

Item #7 on this breakdown which doesn't show the part #. You don't want to get it anyway as it will always break!Best to find a stronger type heat sensor,or have the fan on a toggle switch as many have done. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
Red/white is the tail light,orange the brake light.
Your link doesn't show up on the solenoid.

 

OK, I think that is the exact broken part. what does it exactly do, and if the wires are disconnected the fan runs?

and the solenoid i used has 3 posts. 1 for the starter from the key. and 1 to battery other to the starter

 

also, how is the brake light switched, I have no rear brake setup on this quad as that part of the tranny broke off, its rear wheel drive only, and front brakes only

 

Most of the time vibration causes this cheap sensor to break and short out triggering the fan. It's mounted at the wrong place to begin with(on the motor mount bracket,not on the engine)PLUS a lot of air cooled engines don't have fans and get along fine! This is a Polaris after thought on the fan on a 300.I'd just wire up a toggle and use the fan only in pulling,slow moving situations. When the sensors were ok,the fans hardly ever came on anyway unless you were in deep creek beds under loads with little air flow.This is from what most of the owners told me. If the solenoild is hooked up right,has 12 volts to the small power wire and the battery and starter wires are ok,then you may have a starter/bendix problem. Just jump the two posts on the solenoid and see if the starter turns over. The brake light is pressure switched at the brake line junction block.Brake fluid pressure from the hand brake triggers it. Item #29. http://www.cyclepartswarehouse.com/f...1995&fveh=5399

 

Ok. Most of the day messing with it. I did jump the solenoid and it started with out pulling the cord. I am getin no power in or out of the start button. I will mess with the brake lights another day. But the solenoid is good. I guess I will be tracing wires once I buy a battery. An with the fan. I will just cut it out of the harness and wire it up separately.

 

Trace the ignition switch wiring going to the main terminal board along with the left control switch wiring. Terminal board connections are color keyed.

 

I will when the weather is nicer. In the past month of me owning this the plastics have been off and on over a dozen times. It's stayin together for a while now. I will either use my jumper or just pull. Next paycheck I'm buying the battery. Know of a really durable one that I won't need to replace in a year or 2. And that's why I need a wiring diagram/ PDF service manual. My main computer section is just a web of wires. I'm gonna have to hit it with some zip ties soon!