So I have question along the same lines but having issues - I picked up a 2002 Trail Boss 325 as a project for me and my son for this Covid 19 Summer so he has something to do. But the bike was not wired - all wiring was gone -So I got a wire harness and I got everything wired except the ignition ( It has a 4 pin plug and the person who sold it to me had a replacement ignition but it is 6 pin). That is where I am stuck = I have a 2002 Polaris Trail Boss 325 and the ignition plug 6 pin plug - 3 position ignition On/OFF/Crank Start. The problem is I have a 4 pin plug 2 position ignition plug wire. On/Off and the instructions that were sent were not helpful at all. So My question is starting from pin 1 on the 6 pin plug (Blue) pin 2 ( Orange) 3 (Green) 4 (White) 5 (Black) 6 ( Yellow) / But on my plug I have pin 1 as Red/Black stripe 2 wires together pin 2 ( Brown 1 single wire) , pin 3 (2 black wires together ) and 4 pin is 2 solid red wires together. ( I do not know how a 4 pin wire plug is supposed to convert to a 7 wire conversion. Any help would be a appreciated. Im sure there is someone who has ran into this before the parts diagram calls for a part # ? which has changed to 6 pin On/Off/Crank but the original is a 2 position 4 pin plug with On / Off. I really need help - thanks.
G3M
Ok i just looked at this diagram very intensly and think ( if Im correct it is from a 2000 trail boss it looks identical to the one I have.) So thank you for that. I something still messed up so waiting on new solenoid - carb and wire harness i found the correct - 2002 325 trail boss wire harness with ignition 6 pin and key for $99.00 ( as far as frustration it worth it to work with the right tools for the job ) the correct wire harness will make all the differnce and then with new solinoiniod ( mine has a big hole in it) and a new carb just because the carb rebuild kit was 56.00 and the whole carb from a good company was $37.25 plus tax ( can't beat that for a exact match) after all is said and done i will have less the $150.00 in parts and hopefully up and running. Ill keep you updated on the progress thanks for all your help - I was just fighting a loosing battle when all the wires are miss matched cut and spliced together one not knowing where the other end goes and trying to figure what goes where - it was fun but a pain. So I think my best bet is start from scratch the right way with the right harness and right ignition and go from there.
I'm just as fallible as the next person - I discovered I posted the wiring diagram for the 2001 TB 325 - here's the Correct diagram for the 2002 TB 325 - it has a 6 pin key switch where as the - 2002 was more closely wired the same as the 2003 - sorry about that, but yes, the 01 325 was more similarly wired to the Trailblazer - big change in 02
![140386]( "140386")
Now thats better - Im not crazy ( I do have the wrong wire harness ( ILL be damned) Thank you - I ordered the other wire harness the correct one it will be here on the 21st. Thank you for proving Im not nuts and chaseing this wireing has been dificult to say the least when your seeing and reacting to certain connections thinking they are one thing but in actuallity they are another - It can get frustrating. I think Ill wait till I get the new wire harness and the soleiod and the carb and then start over. Thanks for posting that info it will help me out tremendosly.
I might confuse myself, but I strive not to confuse those I'm trying to help and for that I apologize - it was a careless error on my part to post the wrong year wiring diagram.
It's all good even the best of us make mistakes - But ill tell you what it was alot of fun chasing my tail around the wiring thinking it was right and I was wrong. But now that I have the correct wiring diagram ( Thanks to you) and I have a new wire harness on the way with a 6 pin key ignition ( I should be able to figure out the rest). Thanks for your help.
Got it all figured out thanks for all the help. Here is what it turned out like. From this Rat bike to this - Not bad.. Runs great now and everything works thanks Latebird. Tried to send a video of it running but it was to large. Anyway thanks for all the help.
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