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you have a pinched wire someplace in your wire harness. maybe a melted spot also could cause this.hot wire shorting out to ground on frame. anything you had loose lately. under gas tank , wires got against exhaust pipe, wires rubbed bare from wear ? broken wire in harness could cause it.
When you "hot wire" an ATV with a battery is the same as leaving the key on 24-7. This is not recommended..A good locksmith might be able to help you resolve your "switch issue"
BUT.. the brown wire and the gray wire(both are ignition switch wires).. connect them and you should have power
I would start by checking the fuses for the radio and heater. they are most likely blown. you would have shorted it out when you touched the negative and positive posts together. Then i would check the wires to the radio and heater to see what the condition is of the wires.
Here is the lowdown on Polaris Sportsman 700-800 T-Bap wiring:
Symptoms of broken Temp/Baro sensor wires:
1. The ATV will run very erratic at idle.
2. The "CHECK ENGINE" will sometimes come on.
3. Diagnostic codes 41 and or 45 will be present.
4. Fuel mileage will be poor.
5. Exhaust will smell really rich. Sometimes even black smoke can be seen from it running so rich.
How to test if the Temp/Baro sensor wiring is broken:
1. Turn the key switch on and off 3 times leaving it on the 3rd time. This puts the ECU into diagnostic mode. If codes are present their numbers will be displayed on the instrument cluster. When all codes have been displayed "End" will appear on the cluster.
2. Remove the seat and locate the sensor on the air intake tube. Unplug the wiring to the sensor by pressing down on the tab on the top of the connector. DON'T PULL THE CONNECTOR BY IT'S WIRES!!! Pull back the vinyl tubing that covers the 4 wires going to the connector. Gently pull on each wire with your fingers. The wire should have no stretch and feel solid. All the wires should feel the same. If one or two of them feel weak and stretchy chances are you have a broken wire. Is what happens is the wire breaks inside the insulation so it appears to still be connected.
Why do the Temp/Baro sensor wires break in the first place?
1.The problem with the current Polaris wiring is too short and Polaris used 7/32 stranded 22AWG wire. This wire has a very low strand count and should not be used in applications where vibration occurs.
2.The next problem is the mounting location of the sensor it is in a vibration prone spot on top the air intake tube going from the air box to the throttle body. Next time you're bored take the seat off and rev it up in neutral. That intake boot and sensor vibrate to the point where it looks blurry. The combination of these engineering flaws causes the cable to break in a big hurry.
The Polaris repair kits keep breaking. Why?
1. The replacement kits from Polaris use the same 7/32 strand wire that can't withstand vibration.
find a heavy duty one on the internet or ebay................
well if your wires fried then your battery was around 20v which means your voltage regulator was bad. you need to purchase a new one of those as well. as for the wiring diagram, if the wires around the battery had been fried. are they intact or completely burnt without you being able to locate to which each wire connects to?
one of your repaired wires is not getting power or ground.. Recheck your wires,.
And most likely look farther up the wire loom for burned threw wires..
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