2005 Polaris ATP 500

[Ahren Longo]

Yeah I know its been a while since I've been on but, I've recently aquired a 2005 Polaris ATP 500. As ya'll well know I'm sure that these things are notorious for faulty ECMs and they are made of unobtanium. I got this one from my brother. I've unpotted the old ECM and tested the components and have concluded that they don't flow the board properly from the factory so that's why they crap out.  I've also done some research and found that if you take the harness and Stator and flywheel from a 2004 its basically a plug & play application and it eliminates the need for the ECM. Why the heck they put it in anyways is beyond me. I'm going to devise a way to make a plug & play adapter harness that eliminates the need for the ECM and restores the wheeler to use. Has anyone tried this before and had any luck? I've been trying to locate a wiring diagrams online so I can compare the 2004 to the 2005 but they're pretty hard to find.

[Old_ATV]

I need a wiring diagram for early 90's Kawasaki Bayou 300 4x2 if any one has one of those.

[92BayouB]

looking for an 89 bayou

[Ahren Longo]

Well I got the Polaris fired up yesterday. I was mapping out the wiring harness and found some corroded pins, typical. I also found that the grounding points on the frame were still painted and the terminals were corroded. I also happened to have another ECM that was the original one that was supposedly bad. After cleaning connections I plugged in the ECM to see if I could get any kind of life so I could map power out. Wouldn't you know it the dang thing powered up. I put it some gas and she fired right up. I rode the wheels off it for a few minutes until she started starving for fuel. Gotta get that issue worked out, but I'm going to continue mapping out the ECM inputs and outputs so I can have a bypass solution.

[Ahren Longo]

If anybody cares I got the ECM inputs and outputs mapped out. It does a couple of things. Its the voltage regulator for the stator, It controls the locker in the rear end and distributes power to the electrical system. I figured out how to bypass it all, except the stator, using jumper wires. Developement is under way for a plug & play bypass harness equipped with fuseable links and a control relay for the locker system if anyone is interested. My only hurdle I guess is finding a voltage regulator to use.

[roblyn]

Hi Ahren, I am interested in your work as we have a 2005 ATP 330 that the ECM seems to have failed and was wondering how to do away with it. It has been showing hot for a while now off and on. I have deleted the diff lock and 4wd is automatic anyhow. I would be happy to just get it to start and run and charge the battery.