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2004 Polaris 500 ATP Wiring Diagram Needed!!!

35K views 89 replies 20 participants last post by  LATEBURD HERE 2 HELP  
#1 ·
Hello,

I am having some electrical problems with my 2004 Polaris 500 ATP and am in need of the wiring diagram for this machine. Can anyone please help me out?!?
 
#6 ·
Thank you for this very much! I really appreciate it and I will let you know if I need the full.

THANKS AGAIN!!
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#14 ·
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#19 ·
Welcome to the forum
 
#43 ·
I have a 2005 Polaris ATP 500 4x4 and can not figure out what this part is called brown wire in module gets hot when running so want to replace it here is a pic of the module - Someone before I got it put led lights on bumper and thinking they wired something wrong - at first i thought it was a voltage regulator/rectifier but that is mounted on the rail support by the radiator - any help would be appricicated - Latebird you have been awesome in the past helping me figure things out do you have a 2005 Polaris ATP 500 4x4 wireing diagram or manual i can maybe figure this out with but anyone that can help it would be much appriciated - I realy want to get this thing running right again I love it and need to use it on my property. Thanks ion advance.
 

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#48 ·
It is mounted in the location of the Differential solenoid switch. What are the colors on the harness (not the module). I suspect you have a bad rear solenoid controller. Brown wire is ground, if it's hot then too much current flowing. The module is supposed to supply the diff solenoid with 12dvc for 1 second, then step down to a few volts. Do you hear the rear diff solenoid click when the key is on (motor not running) and gear selector in L or H? There is a sticky I just did on this module (no longer available) and how to test and replace it.
 
#51 ·
Well it was running fine before i noticed the wire getting hot - it was actually the blue wire under further observation that stated heating up and didnt want to run it till after the problem was diagnosed. So you think its a rear diff solenoid controller? Ill investigate that - Thanks.
 
#50 ·
Latebird it looks like someone wired the fan sensor and front led light and transmission sensor into a voltage regulator with 5 wires the 5 wires got into a plg and connect to the wire harness but doesnt look factory - just not sure.
Thats all i can guess is something is wrong in kansas. Im thinking i might have to do some rerouting ot take the led lights out of the equasion. and see if it makes a differance.