Latebird - Gave me this info which was very helpful - thank you

#9 • 9 h ago
OK - if I follow you correctly; the wiring harness has a 4 pin plug for the key switch and you want to install a 6 pin switch.

Part 4010278 is a blank key - the switch is part number 4010390 which superseded to 4012164 @ $95

As long as you have the 6 pin plug for the wiring harness this is a simple conversion. The 4 pin switch connected the red to the red/blk when in the on position and blk to brn when in the off position.

Using the diagram below: the first pic is of the six pin 3 position switch with it's wiring as used on the 2007 TB 330.
The second pic is the 4 pin 2 position switch used on the 2000-02 TB 325.
The wiring harness should have seven wires to a 4 pin plug.
Remove the terminals from the 4 pin plug and insert them into the 6 pin plug in this fashion:
Terminals A and B will be unused
red to C
red/blk to D
brn to E
blk to F

Red is hot
Red/blk is hot with the switch on
Brn is ground
Blk is ignition kill

Switch on red connects to red/blk
Switch off connects blk to brn

Got it?

 

Well I tried the -
Terminals A and B will be unused
red to C
red/blk to D
brn to E
blk to F
But as soon as i turn the key and hit run it engages the starter and doesn't stop until i turn key off.
I tried the picture as well

Pin one through 6
Pin 1 not used
Pin 2 not used
pin 3 both red/black wires
Pin 4 both red wires
Pin 5 both black wires
and pin 6 1 brown wire and got same reaction.

This bike was a project i new that going in the wire harness / according to the wire diagram i have for a 2002 polaris 325 trail boss () looks like the harness with red/black and red and black and brown goes to a 2000 trail boss the wire code colors are different in the book. I'm not sure but this wire design
Terminals A and B will be unused
red to C
red/blk to D
brn to E
blk to F - i can get it to fire over when I go from off to run and it starts cranking but then to stop the cranking I need to turn the key off once it starts and leave it on run and it will run ( but that is very strange ) I should be able to turn the key to on position and then turn the bike to run and then turn the key to crank position and turn it over. But that is not the case.
I dont have the old ignition to refferance
The ignition 4 pin plug was wired as pin 1 - both red/blk wires pin 2 single brown wire pin 3 both black wires and pin 4 was both solid red wires on the harness.
The ignition I have is a Quad Logic 6 pin ignition 3 position On/Off/Crank. I'm having issues with figuring this out to work correctly.
I would have started a new thread but I am new to the forum and don't know how. So any help is appreciated from anyone at this point. Im tempted to just buy another ignition 4 pin (On/Off) and plug it in if I can find one. But the book calls for the replacement being a 6 pin connector. An y advice is appreciated and welcome.

 

All this info was on a 8 year old post since i did not know how to create a discussion - But I figured it out so here is all the info from that post if that helps any - Any help is appreciated.

 

I am not sure it came with the bike but it was off of it the only reason I would think it would be not the right harness is because it has a 3 prong plug for a head light and the 325 trail boss does not have a head light ( but that could be by default) the other reason) is the key ignition wires are red/black and red and black and brown. But the manual says the 2002 trail boss from 2001 and later the key ignition wires are red/black and black and brown and red/white. There seems to be a discrepancy. So im not sure. I hope that helps.

 

Ok after further investigation on this wire harness I dont think it is a OEM 2002 Polaris Trail Boss 325 wire harness ( I think by all the info I have found it looks to be a 2000 Trail boss wire harness) since the OEM 2002 trail Boss has a 6 pin connector ( according to a pic i saw of a OEM wire harness for 2002 trail boss 325) the OEM has 6 pinsThis is what the OEM wire harness looks like - I think.

 

But the one I have has a ignition plug that is 4 pin plug ( so I think I need to get a new harness to make this work) ( I think the one one that came with the bike is a ( to best I can come up with a 2000 trail boss 325 ) it has different ignition plug I think that is why Im having so much issues with the ignition wiring - Only thing that makes sense. So ill start all over and do it right instead of trying to make something fit that was not made for this bike ( But now I know) so knowing is half the battle. Unless someone has a good idea how to make this 4 pin plug work with this 6 pin key ignition.here is what the plugs look like-

 

So now you can see where my problem is and if you can help figure a way to make it work - or start all over with a different wire harness.
This is what the bike looked like when I got it for $450.00 and this what I have done so far.

 

Amazing what a little elbow grease and a heat gun can do to revitalize atv plastics. See the results no bad after removing all the old paint.

 

When Im done this bike will looking like a whole new bike. Just need help on the ignition wiring if any one has nay ideas please feel free to speak up. Thanks for looking at my $450.00 ( Restoration of a 2002 Trail Boss 325 ) it gives me something to do during all this Covid 19 stuff - and gives me and my son something we can work on together.

 

The 2002 TB 325 did not share the wiring harness with any other models, but get the wires from point A to B ant it will work.

What's the VIN so I can verify year and model?

 

Vin # 4XACA32A22661033 and i think the guy i got the bike from just put this wire harness with it because it did not have anything wired when i got it. Im thinking it is the wrong wire harness.

 

10 digit says its a 2002 right?

 

looks like im missing a number hold on ill get the title.

 

4XACA32A822661033 - sorry

 

 

This came from doing a vin search on the atv. It shows its a 2002 - i definatly have the wrong wire harness I think.

 

But i have the bike running - i have to turn the key to on and then go from off to run on the left handel bar and then once it starts i turn the key off and it stays running. Weierd i know but it works for now till i get a 4 pin key ignition i ordered or i get a 100.00 wire harness which is the correct one - but then i have to start all over with a new harness. Someone had the great idea to put a winch on it an tried to tie in the wireing to the harness and really screwed things up = so trying to work with what i got. ( but best case cenerio is to buy the wireharnes use the key i have and call it good). But im old school improvise overcome and adapt - when all else fails then resort to conventental means. MORE MONEY.

 

But Im getting there just a few hicups along the way.

 

Like i said in a previous post - I think this wire harness is for a differnt bike because the trail boss 2002 325 that i have seen does not have a 3 prong plug for a head light it has to lights down on the front bar. This one has a plastic cover over where a head light would be mounted.

 

Get back to me when you have time and give me your thoughts on this - I value others opinions.

 

The ignition is killed by connecting the black wire if the CDI unit to ground - now there is a red/wht wire that is a switched power wire - there is also a wht/red wire that activates the solenoid - if red/wht is connected to wht/red, that would explain the starter running was soon as the stop switch is turned on.- putting the run switch in the run position connects the red/blk wire to the red/wht - with the run switch in run, lifting (pushing up) on the switch connects red/wht to wht/red to activate the solenoid, but both the key switch and the handlebar switch are suposed to connect black to brn (ground) and kill the engine, so either the LH switch assy is defective, wired wrong or the key switch is wired wrong - try turning the key switch to the start position - if that kills the engine, then you just need to swap the blk and brn wires on the key switch to the currently unused terminals.

 

Ok so I switched the black 2 wires to pin1 one which is green on the plug and switched the brown wire to orange pin 2. Now when the key is on it does not start until i put the LH button to run. Great.
So know if i turn the switch to the run position before truning the key to on position nothing happens - Great ( so when i have it in the run position and turn the key it fires over) So I guess with this wire harness i wont be able to use the 3 position ( crank) it looks like it is on or off and thats it - Im ok with that. Thank you so much you have been a tremendous help. Does it sound like this what should happen? LH bar switch to run and turn key and it starts. It also works in reverse if i have the key on and the run switch off and then hit it to run it starts. I think there still might be a wire crossed but Im making progress for not having anything to go on when i got it.
What are your thoughts?

 

I was not sure what wire Black or brown to put on pin 1 ( I miight have them backwards) pin 1 is black, pin 2 is brown pin 3 is red , pin 4 is red/black pin 5 and 6 are not used. Currently.
Should i change anything in your opinion?

 

I checked the white/red wire and it goes to the solenoid and the red /white wire im not sure of what red/white wire you mean i have one that goes to the magneto and one that goes the fan thats about it.

 

Please do not confuse red/wht and wht red

There is a wht/red wire on the stator that goes to the CDI box

There is a wht/red wire that goes from the LH switch to the solenoid

If the wht/red wire is connected anywhere to the wht/red wire, the solenoid will close and the starter motor will run.