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2004 Polaris 500 ATP Wiring Diagram Needed!!!

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#62 ·
Lol... your right amazon. But guess what I found... I took your feedback and did some more checking. To this point I have been using chasie ground to check for power. I took your instructions to use pin8 and using pin8 no power.. I used your schematic and traced pin8 to the headlight which didnt work either. Disconnected the headlight plug and it was cut. All three wires cut, repaired all the wires and walla everything works, even the old speedometer. Way cool... the previous owner must have been troubleshooting the problem and cut the wires. Going to clean the fuel system and fire it up this weekend. I'll keep you posted on final out come. Thanks for all your assistance. Have a blessed day.
 
#63 ·
Well I have repaired the wires, rebuild the carb and got it running nice. However went to turn it off and it will not shut off. I replace the ignition switch and still won't shut off. won't even shut off with the handlebar switch. all the ground wires appear to be solid. Does anyone have any ideas what path I should take now. I have review the schematic and really not sure which path will to take, one goes to handlebar switching and other goes to blk wire 02 to CDI. Any assistance would be appreciated. I am so close to getting to actually ride this thing. Since i got it all i have been doing is working on it trying to getting it in running condition. runs now, just won't shut off, wasn't really prepared for that kinda problem and it caught me off guard. thanks for anyone that can assist with this.
 
#65 ·
You won't believe what I found, I was cleaning ground wires and other connections and I removed the brown ground wire on the CDI and the motor shut off. started looking at the schematic and as you pointed out i should be able to ground the black wire to kill the engine. So I was putting the ground wire back together and I removed the CDI plug and CDI and when I looked and the back of the CDI there was this printed note. " remove the blue wire if machine will not shut off" what the heck, so I removed the blue jumper wire and everything works perfect. runs greats, shuts of and all electronics work perfect. LOL... the misprinted blue and spelled it "bule" took me a minute to figure out they meant "blue" lol... I was looking up what "bule" was, that made it even funnier once i figured out they meant "blue". well lets see what happens. I am going to order another CDI just incase. thanks for all your help, you have been very helpful. May GOD Bless you in return.
 
#67 ·
OK - so I connecting the black wire of the CDI unit to ground and killed the engine as it should. replaced the fuel pump and still crappy. at Idle it sounds great for a few minutes then starts actin up, if you drive it is runs great with open throttle but at lower speeds and idle speeds it runs crappy, sputtering and if you stop to idle it will die. if you let it cool of for a few minute runs awesome for a few minutes then starts acting crappy again.

Any suggestion what to try next. Could it be the old speedometer, or could the CDI be acting up after it get warm. Not sure where to go next.

some else of interest, when you first start the engine it has a flashing wrench in the speedometer on the left side of the speedometer. goes away and then sometimes comes back. I have google it with nothing helping understand what that wrench is. I thought it was like a service engine light but not sure. any help would be appreciated.
thanks
 
#68 ·
update - I have worked on this problem for weeks, last night I removed the carburetor and found crud in the bowl (probably from the old fuel pump), I replaced the fuel pump still starving for gas. I removed the carb, overhaul it again and this time i put the main jet back with the shim. when i rebuild the carb couple weeks ago I forgot to put the shim back so the vacuum for the carb has not been working properly hence running crappy. put everything all back together and that think hauls butt. purrs like a kitten, and tons of power. So overall I had, bad grounds wires, some cuts wires, old gas, and carb needed overhauled. all that repaired and it runs perfect.
Thanks for all your help. hopefully I can return the favor one day. I have never joined a forum before so this was beneficial and I look forward to being a member.
 
#70 ·
I'm working on an ATP 500 and have replaced just about everything in the ignition system except the coil, stator, and the CDI box. The coil and stator show close to normal ohm readings when tested. The problem is when it is started it runs great, but the engine dies after 20 to 30 seconds. I've tried installing 3 different replacement CDI boxes but none of them work. I don't get spark when starting the engine. I'm open to any suggestions on this one.

Thank you in advance!
 
#71 ·
harneysj said:
.......replaced just about everything in the ignition system except the coil, stator, and the CDI box.
Click to expand...
I sent you the service manual.

The ignition system consists of the stator, cdi box, coil, spark plug, spark plug cap, flywheel and the wiring connecting the components.
 
#72 ·
lateburd said:
I sent you the service manual.

The ignition system consists of the stator, cdi box, coil, spark plug, spark plug cap, flywheel and the wiring connecting the components.
Click to expand...
Thanks for that. Is there anything different about the aftermarket CDI boxes that they don't work at all? Polaris discontinued this one so I'm still stuck. Can I get an '03 CDI and just connect that to the wiring harness?
 
#73 ·
harneysj said:
Can I get an '03 CDI and just connect that to the wiring harness?
Click to expand...
Yes - the 03 was the same unit - the CDI unit was the same for the following models

2003 500 MAGNUM 4X4 HDS A03CD50FB
2003 500 MAGNUM 4X4 HDS A03CD50FB
2002 500 MAGNUM VL HDS A02CD50FB
2004 A04CH42AA SPORTSMAN 400 A04CH42AA/AE/AG
2004 A04CH50AA SPORTSMAN 500 A04CH50AA/AC/AE/AG
2004 A04JD50AA ATP 500 4X4 A04JD50AA/AB/CA
2004 A04JD50AA ATP 500 4X4 A04JD50AA/AB/CA
2002 ATV PRO 500 4X4 PPS C02CD50AC
2002 INT'L BIG BOSS 6X6 A02CL50DA
2002 LUH 6X6 PPS C02CL50AB
2002 MAGNUM 500 A02CD50AA
2002 MAGNUM 500 2X4 HDS A02CB50FC
2002 MAGNUM 500 RMK A02CD50AB
SERIES 10 PTV 4X4 C10CD50AA
SERIES 10 RANGER A10RD50AA
1999 RANGER A99RF50AA
SERIES 11 RANGER A11RB42AA/A11RD50AA/AB/A11RF50AA
SERIES 11 RANGER A11RB42AA/A11RD50AA/AB/A11RF50AA
SERIES 10 RANGER A10RD50AA
SERIES 10 RANGER 500 6X6 A10RF50AB
2002 SCRAMBLER 500 2X4 A02BA50AA
2002 SCRAMBLER 500 2X4 A02BA50AB
2002 SCRAMBLER 500 4X4 A02BG50AA
2003 SCRAMBLER 500 4X4 A03BG50AA
2002 SCRAMBLER 500 4X4 FREEDOM A02BG50AC
2003 SPORTSMAN 400 A03CH42AA/AB/AC MAGNETO - A03CH42AA/AB/AC (4975277527D12) 3087169
2002 SPORTSMAN 500 ALL OPTIONS A02CH50
2003 SPORTSMAN 500 HO A03CH50AA/AB/AC/AD/AE/AH/AJ
2003 SPORTSMAN 6X6 A03CL50AA
2002 SPORTSMAN 6X6 A02CL50AA
 
#74 ·
On my 2004 ATP 500 HO, I had tried several ebay / amazon CDI boxes and none of them worked. I finally spent more $ and bought a Procom CDI box and it has worked well for almost a year now.

It's hard to say, but it does feel like it has more power than with the original box. I suspect they've increased the timing along with the rev limiter. I only run non-ethanol fuel. Around here the only non-ethanol pump gas is 92 octane so no worries if the timing is advanced for me.

Procom
 
#75 ·
lateburd said:
Yes - the 03 was the same unit - the CDI unit was the same for the following models

2003 500 MAGNUM 4X4 HDS A03CD50FB
2003 500 MAGNUM 4X4 HDS A03CD50FB
2002 500 MAGNUM VL HDS A02CD50FB
2004 A04CH42AA SPORTSMAN 400 A04CH42AA/AE/AG
2004 A04CH50AA SPORTSMAN 500 A04CH50AA/AC/AE/AG
2004 A04JD50AA ATP 500 4X4 A04JD50AA/AB/CA
2004 A04JD50AA ATP 500 4X4 A04JD50AA/AB/CA
2002 ATV PRO 500 4X4 PPS C02CD50AC
2002 INT'L BIG BOSS 6X6 A02CL50DA
2002 LUH 6X6 PPS C02CL50AB
2002 MAGNUM 500 A02CD50AA
2002 MAGNUM 500 2X4 HDS A02CB50FC
2002 MAGNUM 500 RMK A02CD50AB
SERIES 10 PTV 4X4 C10CD50AA
SERIES 10 RANGER A10RD50AA
1999 RANGER A99RF50AA
SERIES 11 RANGER A11RB42AA/A11RD50AA/AB/A11RF50AA
SERIES 11 RANGER A11RB42AA/A11RD50AA/AB/A11RF50AA
SERIES 10 RANGER A10RD50AA
SERIES 10 RANGER 500 6X6 A10RF50AB
2002 SCRAMBLER 500 2X4 A02BA50AA
2002 SCRAMBLER 500 2X4 A02BA50AB
2002 SCRAMBLER 500 4X4 A02BG50AA
2003 SCRAMBLER 500 4X4 A03BG50AA
2002 SCRAMBLER 500 4X4 FREEDOM A02BG50AC
2003 SPORTSMAN 400 A03CH42AA/AB/AC MAGNETO - A03CH42AA/AB/AC (4975277527D12) 3087169
2002 SPORTSMAN 500 ALL OPTIONS A02CH50
2003 SPORTSMAN 500 HO A03CH50AA/AB/AC/AD/AE/AH/AJ
2003 SPORTSMAN 6X6 A03CL50AA
2002 SPORTSMAN 6X6 A02CL50AA
Click to expand...
Lateburd, I can see this is an older conversation but so am I, my son showed up with a 2004 Polaris 500 HO ATP and wants some help getting it running. We have done most of the starter mechanical, changed all fluid, spark plugs, filters air,oil,fuel, diff. fluids now starting to track down the electrical for a NO Start. Is there any chance you still have the Service Manual available for this machine, if needed I can have him send me the VIN# to help narrow down. I have 2006 Polaris S700 EFI Sportsman a pair, so the are somewhat different. Thank you for any help and if not that ok to have a great day!!!
 
#77 ·
P100kman said:
Lateburd, I can see this is an older conversation but so am I, my son showed up with a 2004 Polaris 500 HO ATP and wants some help getting it running. We have done most of the starter mechanical, changed all fluid, spark plugs, filters air,oil,fuel, diff. fluids now starting to track down the electrical for a NO Start. Is there any chance you still have the Service Manual available for this machine, if needed I can have him send me the VIN# to help narrow down. I have 2006 Polaris S700 EFI Sportsman a pair, so the are somewhat different. Thank you for any help and if not that ok to have a great day!!!
Click to expand...
I think yooper got you covered
 
#78 ·
Yooper did help me tremendously and we are in the garage at 15 degrees working on it now, When it was parked it had no gas in it so the carb is not plugged or gummed up, tank is clean, as if he pu denatured alcohol in it to evaporated the condensate out of it before parking it. Well taken care of machine> Thank you both for the concern and help.
 
#79 ·
P100kman said:
Lateburd, I can see this is an older conversation but so am I, my son showed up with a 2004 Polaris 500 HO ATP and wants some help getting it running. We have done most of the starter mechanical, changed all fluid, spark plugs, filters air,oil,fuel, diff. fluids now starting to track down the electrical for a NO Start. Is there any chance you still have the Service Manual available for this machine, if needed I can have him send me the VIN# to help narrow down. I have 2006 Polaris S700 EFI Sportsman a pair, so the are somewhat different. Thank you for any help and if not that ok to have a great day!!!
Click to expand...
Welcome to the forum
 
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LATEBURD HERE 2 HELP
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