2nd fuel line coming from top right side of carb?
 

OPT or anyone else,

Here I am again with yet another Polaris project I'm trying to save from the scrap heap.

This one is a Sportsman 500 RSE 1998.

I found so many things jerry-rigged, it wasn't even funny. Many that I think took more effort than buying the proper replacement part..........but I can complain about that all day.

I've got most sorted, but am a little stumped on this extra fuel line.

The dumb-dumbs instead of simply replaced the 3-way fuel valve for $15, they cut, plugged lines with bolts, etc and added a regular universal 2 way valve between the main tank line and the carb. Just plugged the reserve line with a bolt.......ugh.:huh:

Anyhow, I've got a new 3-way coming and all lines sorted out as to what goes were with the exception of the line which is connected to the upper right side of the carb if you are sitting on the ATV looking fwd. I attached a pic. The other end was plugged with a bolt/clamp.:crazy:

Where would that line connect?

I have the gas tank main and reserve line going to the 3-way valve, the outlet of the 3-way valve going to the inlet of the carb on the lower left side, and the vent/return line (seen in the pic) appears to be correct so I haven't touched them.

Thanks for you assistance once again.

Right side of the carb is the vacuum line leading to the fuel pump marked "P" Look at #2,3,4. Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse #3 into the fuel pump comes from the fuel valve. #20 is the fuel valve with the two lines from the tank,plus the nipple at the rear that has the line for the fuel pump inlet(top line of the fuel pump)http://www.cyclepartswarehouse.com/f...1998&fveh=5461

Well, crud.....guess I don't have them figured out after all....lol. "Engine Mounting" I would have never looked there. I did look at the microfiche for the carb which didn't help me. I need to go have another look at the ATV now....standby

Well, that explains a lot. Previous owner had bypassed the fuel pump and had the main line direct gravity feeding the carb. No wonder it was running so bad. I do not see a fuel pump on this machine. Where about would it be mounted? The Microfiche doesn't show it. I think I have a PDf file of the maintenance book. I'll do some digging in there. Days like this I wish I still had one of the other Polaris's to compare.

http://www.cyclepartswarehouse.com/f...ion_detail.asp

1998 Polaris SPORTSMAN 500 (W98CH50A) Engine Mounting B | MRCycles

Okay, I see where the fuel pump is supposed to be and what a surprise, it's not even there. Boy, sometimes I kick myself for getting these jerry-rigged things from other people....oh well. Pump is now on order for $12.99. I'll have to figure out the fuel line puzzle once I get all parts on hand by next weekend (with the holidays happening).

Thanks OPT.

What Forrest Gumps' momma said about "life is a box of chocolates,you never know what you're gonna get". So true..Applies to used atvs also :) Not hard on figuring out the fuel pump hook up. Just holler if you need help..

Ain't that the truth. It'll be next weekend by the time I get all parts ordered and get back into town after our short Christmas trip.

Merry Christmas to you and yours OPT.

Sorry for the long delay in getting back to this one OPT. I ended up having to do a head gasket on this pig too, so I forgot to get back on here to update the post. Head gasket all done and no real surprises there thank goodness. I did find the rear brake line was disconnected and the 4-way was plugged with a bolt....wtfalker?! Fixed that too and rebuilt the rear caliper so it works now. Anyhow, I installed the fuel pump, new shutoff valve and corrected all fuel & vacuum lines. She fires right up and seems to be running great (sitting in the garage anyhow). I started to put everything back together and for the life of me I cannot get the dang fuel tank back in place which is needed before I can put the plastics, etc back on. It seems like the fuel tank got bigger from sitting on the garage floor.....lol Correct em if I'm wrong, but doesn't the front 2 tabs coming off the tank go into the slots on the framework? If that is the case, I cannot get the right side tab to align with the hole because the right side of the tank is already pressing against the frame rail preventing me from moving it maybe 1/4" more it needs to get into place. I have been fighting that for the better part of 2 days now. All I can think is I'm going to have to recruit some assistance to muscle it into place, but I wouldn't think it would be a good thing for the tank to be pressed against the frame because of vibration/chafing issues that would result. If anyone has a photo or can take a photo for me I'd appreciate it. Also, Does the fuel pump mount to the inside of the frame rail or the outside? I have it on the inside as that seems to make the most sense with how the fuel/vacuum lines run, but that may be interfering with the tank install as well. Looking at the microfiche it looks like I may have that wrong. Think I'm going to swap it over to the outside of the frame rail and see if that helps. More to come.

Years ago on the first one I pulled off,wasn't paying attention and tried to do the same thing as these were the new generation of tanks.Found out real quick on this. The tab doesn't go into the slot even though it looks like it should. Lift the tank up,tilt the front down and have the tabs go under the slot area. Then the tank will set right down.. Also easier to mount the fuel pump before everything's back on. Mounts on the outside of the frame. Two of the pump bolts are used in mounting to the frame.

Got it in OPT. One, I had the pump on the wrong side of the frame rail. I'm guessing there may have been 1 too many beers that day......lol. Now that you mention it, this was the first year of the tank redesign. I used to have a 90 trail boss and a 97 Sportsman (both neglected projects of course). and the tanks tabs did go into the slots. So, that is all back together now. I appreciate the help. I have one more things to sort out on this thing before putting it completely back together, but suppose I should start a new thread on it if I can't find the answer on my own. I hate to clog up forum threads with questions if the answer had already been posted on the forum or elsewhere. Thanks again buddy. You definitely know your Polaris stuff!

What's the problem? No need to start another thread..

Rokeeedokeeee.

I'm trying to sort out some wiring connections that I found disconnected when I tore this one down for the head gasket and fuel pump stuff. I have the wiring diagram for this model, but it doesn't seem to include the wiring for the speedo. So, here's what I have and what I'm trying to sort out. Here's the 2 Speedo connectors as labeled and below is what I'm trying to sort out.

Speedo connector (6-pin)
Pin A - Red/Wht (power with key on) - for backlighting
Pin B - Brown - common ground
Pin C - Black - it is connected - ??
Pin D - Ylw/Red (constant 12 vdc key on or off)
Pin E - Brn/Wht - it is connected - ??
Pin F - Light Green - it is connected - ??

3 Pin Plug
Pin A - Red - it is connected - ??
Pin B - White - it is connected - ??
Pin C - Black - it is connected - ??

#1) Pin C of the 6-pin connector is the Black wire and it's connected to the terminal board, however the Black wire has a White wire spliced to it with a female spade connector and not connected to anything. It looks like a factory splice job.

#2) Pin B of the 6-pin connector is the Brown wire and it's connected to the terminal board, however the Brown wire has a Red/White wire spliced to it with a female spade connector and not connected to anything. It looks like a factory splice job also.

#3) White wire coming from throttle for the ETC is not connected to anything. Has a female spade terminal. Diagram shows it should be connected to the LR-83 Hub Safety Switch, but I can't seem to find the Safety Switch in question.

#4) Speedo backlighting is inop. I'm guessing a bulb since power and ground are good, but looks like I have to disassemble the speedo to get to it though. (I'm not too concerned on that really).

There were several other disconnected wires but with the diagrams and cleaning up the terminal board to see terminal labels, I got them all sorted out.

Is there a separate diagram for the speedo circuitry so I can learn what wire does what and where these wires should be connected?

Thanks again OPT.

Man you got to be kidding on this.. :)


Speedo connector (6-pin)
Pin A - Red/Wht (power with key on) - for backlighting..... Yes
Pin B - Brown - common ground Yes
Pin C - Black - ?? hub safety switch(module)
Pin D - Ylw/Red (constant 12 vdc key on or off) voltage regulator(rpm)
Pin E - Brn/Wht - ?? ground wire for awd coil
Pin F - Light Green - ?? hub safety switch

3 Pin Plug
Pin A - Red
Pin B - White This plug/wiring goes to the wheel speed sensor
Pin C - Black

And no,manuals don't show any speedo circuitry... Hook up what you know is right then process of elimination on the rest of it..The schematic should help,just trace the wires from the speedo connector on it.. Next time get an atv that a Rottweiler hasn't taken his frustration out on .. :)

Thanks OPT. I seem to be a glutton for punishment getting these things. Just hate to see what could be a great ATV/golf cart/etc going to waste and being neglected.

Like I said, a glutton for punishment.

When I meant not showing the Speedo circuitry, I meant not showing the speedo 2 plugs at all, not the speedo internals. Sorry for the confusion.

So, from what you responded and giving it another look over, I think I found the HUB Safety Module (in plain site under the terminal board it seems....). So I connected the white wire to the terminal board which matched it up with the white wire for the Module (diagram doesn't exactly show that). So, #3 is solved I hope. Now, back to those spliced wires not connected coming from Pin B and C of the 6-pin. See the pic attached. The Black (pin C) and Brown (pin B) are already connected to their respective terminal board spots. What would the pictured wires connect to then? Again, looking at the splice points, they seem factory looking as all the others I found on the harness. Hoping a pic will help. These are my last 2 unknowns now.https://cimg3.ibsrv.net/gimg/atvconn...ff5c8e0439.jpg

Hopefully a pic is worth a thousand words :-/

Doesn't look right on the red/white tied into a brown(ground) as the red/white is a power wire that's hot when ignition is on.But it might be the SPARE red/white that's used for auxiliary equipment that most models have. Again the white and black go down to the hall effect sensor mounted on the right front brake caliper. Look down in that area to see if you can trace these down.

My thoughts exactly on the Red/White. Everything I've ever touched in the past that was a power wire. Why would it be spliced to a ground. I'm going to just clip that off and forget I ever saw it.....lol. Hell, even if it were for an accessory port, it would mess someone up being spliced to the ground side.

Now, as for the white wire spliced into the black (of the 6-pin connector). I pulled the right front tire and traced that sensor all the way up to the 3-pin plug on the speedo. That's not the white wire I'm speaking of. Again, sorry for any confusion.
On the terminal board there's only 2 White terminals (for the aforementioned Hub Safety Module) and those are occupied. Right now the speedo doesn't seem to work (didn't work when I got it either). So I may just let that slide. I can't expect to get everything 100% sometimes. I think it's time to put this thing back together and go play in some mud!

Once again, thanks for all your expertise. Not showing the speedo connectors on any diagrams made this a guessing game unfortunately.

Have a good evening OPT.

Too bad it wasn't a later model(2005) as the manuals do have a dedicated speedo troubleshooting section with pin wiring and trouble shooting checks. The two manuals I have: 96-98 All Models and 1996-2003 Sportsman 400-500 don't have this. These concentrate mainly on ignition and charging and on the schematic barely show the speedo connectors. Later manuals probably wouldn't help you a lot on this and wouldn't be accurate as the speedos are different,more complicated and wiring is different.

Well, at least they learned from their mistakes eventually.....:rolleyes:. Sounds like you have the manuals I have also. Heck, I may even have gotten from you in the past, I can't remember where I found the pdf's. Dayum.....I just got a sticker shock when looking at a new Speedo (99-02 were the same electronic type).....$400!!!, even on eBay....That's nuts. Maybe I'll get lucky and find someone parting out an ATV sooner or later.