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  1. #1
    Kerminator's Avatar
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    Pro 785 motor pulled

    I have the motor pulled on my 97 pro 785. Only thing attached to the motor is the Cdi box. Motor is hanging from the rafters and wires are still connected to the Cdi box. Why didn't polaris make a quick disconnect to the wire loom that runs to the front of the motor to the Cdi box??

    Any tricks to make this thing fully disconnected without getting into the mess of the Cdi box? Or only just unplugging as few as possible?


  2. #2
    Click avatar for tech links/info, donation request K447's Avatar
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    In later years on the domestics Polaris eventually did insert a connector into the stator cable. No idea why it took them so long. Polaris used Deutsch DTM 12-pin on the domestics, but Weatherpack connectors seem to be easier to find.

    You can buy a Weatherpack connector kit with the mating pieces. Sever the stator cable cleanly about a foot from the electrical box, give or take. Battery must be disconnected!

    When you get the connector kit, assign each pin number to a wire color. Write the sequence down for your own records.

    Then install one connector on the stator cable, and the mate on the electrical box stub cable. Make very sure the colors correspond when the two connectors are mated!

  3. #3
    Kerminator's Avatar
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    Thanks for the info. I have seen in previous posts on making a quick disconnect. And I will probably do that when I install the motor. But is there any correct way of disconnecting a few wires inside the box. Or should I just take the whole box out with it and take out the sending unit and mfd cable connector along with the start stop switch.....

  4. #4

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    theres only one way disconnect them one by one no other way around it or just leave them and cut them about a foot away from the box and go on ebay and buy weather pack connectors they work great . I usually use two of them

  5. #5
    Click avatar for tech links/info, donation request K447's Avatar
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    Arrow How to add a disconnect connector to the electrical stator cable

    Quote Originally Posted by Kerminator View Post
    Thanks for the info. I have seen in previous posts on making a quick disconnect. And I will probably do that when I install the motor. But is there any correct way of disconnecting a few wires inside the box. Or should I just take the whole box out with it and take out the sending unit and mfd cable connector along with the start stop switch.....
    Certainly there is no need to remove the entire electrical box!

    Disconnect the battery.

    Cut the stator cable about a foot from the electrical box.

    Tip: Try to position the cut so when the new connectors are in place they will not be laying right in the bilge water in the bottom of the hull. Yes, these connectors are supposed to be waterproof. It is still better if the are not laying in water all the time.

    Remove engine and proceed with whatever work is needed.

    Order the appropriate Weatherpack or Deutsch connector set.

    When it comes in, strip back enough outer covering from the two cable ends to allow you to install the new connectors. Pay attention to the wire color pin assignments so that no colors are cross connected when the two halves are plugged together.

    Reinstall engine when it is ready.

    Connect the connector pairs. Recheck that each wire color is indeed mating to the same color on the other side.

    Reconnect battery.

  6. #6
    Kerminator's Avatar
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    Thanks you guys. Just ended up disconnecting each wire out of the box one by one. But all in all for the first time taking out a pro 785 motor it was fairly simple. The carb side is easy if you have a ratcheting wrench. I did. Pump area was simple. Pipes weren't too bad. Took some time, but not bad. Won't be putting them back in though. Hot seat pipes installed sometime before spring. Think those should be easier to put in as they just lay in and don't have as many mounts.


    Probably will end up putting a quick disconnect in sometime before I install it again. That was the worst part was that Cdi box wire mess. Which by the way was very clean and no water or moisture or sand inside.

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  9. #8
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  11. #10
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    Figured I would share some pictures of the progress. I already miss summer being on these things!

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