I have a 2006 Polaris Sportsman 500 fuel injected with the ECM module gone I was wondering if there was any way that I could rewire it or something to do away with that😅 put another wire harness on it or something thank you what's your thoughts on that

I hear ya. The other option would be taking a 02 wire harness, stator, cdi and coil with voltage regulator off one a guys is parting out and swap everything.

That's what cutting the bluw wire does.

I have a 98 425 Magnum I had the fan not coming on so I replaced the temperature sensor and thermostat and the problem was solved. These Polaris can be finicky this one wouldn't run if the air filter wasn't on correctly I had to replace the filter stand $30 and a new filter $15 then the battery went dead it's always something but when they are running it's a great machine.l got so much money tied up in this bike I might as well enjoy it.

Great video! You did a great job explaining the process and different options available. Removing the fan circuit from the unit removes the load that caused them to get toasty. The 2004/500 that I did this repair on required complete removal of the box as it was burned up and all the smoke was leaked out 😂. Downloading wiring diagrams gave me the details to figure out Polaris circuitry, which aren’t too complex (carb models). Didn’t have extra cash at the time, so I had to get creative. I also wired the fan to the key switch 😅 Speedometers control the ground for the AWD which often fails, so the brown/white wire needs to be cut and grounded. What I like to do on the ones I keep is apply key switched 12v to the grey/white wire on the AWD switch, which will give complete control in all gears as this bypasses the transmission switches.

@@smallgaragehustle Thanks for the advice. cutting the Blue wire with white stripe was the Key to this all.

@@georgehuffert1800 Every Magnum I've worked on has a finicky airbox. Not sure why its just the Magnums.

I would check the ground wires and add a ground to the 4x4. check your hub fluid and replace fluid. If its none of those something in the hillard clutch could be off. You could pull the hubs and see whats going on.

Sounds like your ECM is grounding out. It will probably need to be replaced. I'm in Sheboygan. Polaris had a recall on them. Maybe ask the dealer first if its still covered.

@@TitaniummanGarage as you probably know, the ECM for the ATP (330 & 500) are pretty much impossible to find. This one is not covered by the recall. I was curious if I can direct wire the machine and totally skip the ECM. I don't really care about the turf mode, or even if the speedo and light don't work. I just want it to run so I can use it to haul firewood and plow. If I disconnect the voltage regulator, will I just lose charging capability or am I at risk of ruining something else?

Did you see my video I did 2 years ago? Ecm bypass? It can be done. I used the wiring off a 04 atp without the ecm. It had the cdi and voltage regulator. I changed the stator as well.

@@TitaniummanGarage I did, but I was hoping for an easier, less time-consuming option (if there is one). 🙂

You can just hot wire the fan. But I couldn't stand the flashing hot light. Plus I couldn't change from rpms to milage with it flashing.

Lol. I was waiting for someone to say that. I usually solder them.