ATV Riding - Disable the Reverse Limiter

 

Doug Ledbetter::Hobbies::ATV Riding::Disable the Reverse Limiter

I noticed that many other ATVs have a reverse limiter override button on the handlebar. Not so with the 2005 Suzuki Vinson which is unfortunate. I understand the need for safety, but there may be times when you need a little extra when in reverse (ie- you're stuck in the mud!).

I didn't want to permanently disable the reverse limiter for safety reasons but I did want to be able to optionally disable it when I felt like it. I found instructions for permanently disabling the reverse limiter on the Internet. I have used those instructions and also added a few new things so that you can switch the reverse limiter on and off at your command.

Materials Checklist

  1. One 1N4001 Diode available at Radio Shack for under $1
  2. One Single Pole-Dual Throw (SPDT) switch available at Radio Shack for around $3.50
  3. Three wires each about 12 inches long
  4. One of those nifty blue self-striping wire splice connectors (pictured right)
  5. Two wire butt connectors for 14-16 gauge wire
  6. Electrical tape
  7. Soldering iron and solder

Installation Steps

Note: you can click on the photos to get a larger view!

1. Get your supplies together. You can see the diodes and the SPDT switch I purchased from Radio Shack to the right. There's also a close-up of the switch. The switch allows you to switch the input (center input terminal) to either the left or right output which is exactly what we need. Remember that the switch selects the output pole that's to the opposite direction that the switch leans. For example, if you flip the switch left, the right output will be activated. This information is provided for those of you without an Ohm meter (yes, you really should invest in a multi-meter).

[ Supplies ]

[ SPDT Switch ]

2. Here's where you understand the big picture. The wiring diagram to the right should help clarify the following steps.

[ Wiring Diagram ]

3. Locate the CDI module mounted on the front of the rear storage box. Locate the wire bundle on the upper frame rail going to the CDI module, taillight, and two loose connections. Carefully cut the tape securing the wire bundle to the retaining clip that is mounted to the frame rail. The bundle along the frame rail is covered by an adhesive vinyl sleeve. Peel back that sleeve toward the front of the ATV. You may have to unwrap the tape holding the end of the sleeve. Do not remove the short sleeve covering the branch to the CDI module.

[ Identify the Wires ]

5. NOTE: You may want to refer to the wiring diagram above to help with this and the following steps.

Solder three lengths of wire, each about 12 inches long, to the SPDT switch terminals. On either the left or right switch terminal wire, you will want to solder the diode inline with the wire. I just cut that wire in the middle and soldered the diode in there. Make sure that the diode is pointing the right direction! The diode is acting as a "one way" street in this situation. The cathode end (the end with the stripe on it) should be closer to the switch. Use electrical tape to cover the diode and your solder connections. Make sure there are no sharp solder or wire spikes coming through the electrical tape.

 

6. Find the white/red (white with a red tracer) wire and the blue/red wire. There is more than one blue/red wire so find the one going to the CDI module. Cut the blue/red wire. Attach the end going to the CDI module to the wire leading to the center ("input") pole of the SPDT switch using the butt connector.

Connect the wire without the diode to the blue/red wire going toward the front of the ATV. Connect the wire with the diode inline to the white/red wire. Don’t cut the white/red wire, just use the nifty blue self-striping wire splice connector to make the connection.

The bottom photo shows an overview of the wiring.

[ Make the Connections ]

[ An Overview ]

6. Tape up the wires with electrical tape to protect them. I also applied liquid electrical tape to the back end of the switch to prevent corrosion. The switch will tell you what size hole it needs for mounting. Mine required a 1/4" hole which I drilled through the plastic under the seat. I put the hole near the two pre-drilled holes where the cables for my winch run to the relay which is mounted on the rear storage compartment. Ideally I will eventually add better labels near the switch, but for now I just used a sharpie to write "reverse limiter" and "on" and "off" next to the switch on the black plastic.

Now you're done! Go test it out. It works perfectly for me.

[ Installed Switch ]
I hope these instructions help you out! If you have any questions, please let me know!