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I have a brand new 06 Foreman 500ES and have been reading comments here regarding using dielectric grease in electric connections (like the ES) to help eliminate issues with water getting into the connections. Being new to this, can someone help me by listing what electric connections (ES etc)should get the dielectric grease and where these connections are. Pictures would be very helpful. Also, do these connectors separate easly (like unplugging your vacuum from a wall socket?) or not? Any tricks to the process of disconnecting the 2 sides, adding the grease and re-connecting? Where do you buy dielectric grease? Thanks
 

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Dielectric grease all connections.
I was having problems with my ES shifting so I striped mine down and dielectric greased every electrical connection on it. When I was greasing them I found a few with water and corrosion in them cleaned them out and now no more problems.

The green connector on the right in this pic was the one causing my problems.


 

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Nice job! I'm going to do mine this week. So the rectifier on the back,right side below your seat and below the pod is the main places to hit, anywhere else, o yeah the elec. in the battery compartment
 

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You should be able to find it at most auto parts stores.

This is the one I used.
 

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Hey marcust, there is some more wires under the pod on the left side if sitting on bike,there is a block of 4 connectors in front of the fan did u do them, i cant hardly get to them
 

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QUOTE ("DIRTYFOREMAN500":3lvc6wrj)
Hey marcust, there is some more wires under the pod on the left side if sitting on bike,there is a block of 4 connectors in front of the fan did u do them, i cant hardly get to them
I did every electrical connection even took apart the display and smeared dielectric grease on the circuit board. I wanted to be able to have everything but the snokel underwater without problems.
 

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yeah me to, im doing mine right now, ive done the carb conn, the rear, beside carb on right side in front of pod and below the pod but havent done those ones im talking about how did u get them apart, there four black ones stacked on top of one another
 

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QUOTE ("DIRTYFOREMAN500":770tbxsv)
yeah me to, im doing mine right now, ive done the carb conn, the rear, beside carb on right side in front of pod and below the pod but havent done those ones im talking about how did u get them apart, there four black ones stacked on top of one another
It's hard to explain but I had to stick a very thin screwdriver in between the between the two connectors.
 

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Talk about reviving from the dead...



Anyway--this should be stickied.. its got some good info on how to dieelectric grease your connections, except for on the left side. Stickied both here and on the rubicon forums.
 

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Also guys/gals dont forget the rear end above the right back rim there is about 5 conectors . Since i did my bike it has ran amazing almost beter than before .What i did as well unplug your sensors connectors and grease tham up .when i unplug my angle sensor the connector had water in it and lots.I unpluged evertything including battery
 

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are the angle sensors and all the other sensors along the right rear and in the front? or are those on the engine? So far I've got a to do list for the right rear bunch of connections, the front, and the left hand side.
 

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Top front as the pics show , left front behind fendor as well left side plastic has to get removed from engine and under the exhust pipe is the angle sensor whcih is low and more conectors around the top by the carb/air than some inthe rear more to the right and right behind rear fender also other sensors like back of the motor an the bottom
 

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so the angle sensors dont plug directly into the engine or anything right? they just go into a wireharness and all that fun stuff?
 

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QUOTE ("CDNTRAILEDITION":36qzjay8)
so the angle sensors dont plug directly into the engine or anything right? they just go into a wireharness and all that fun stuff?
well i got both ends the one going into the computer? and the one to the sensor and as well all around it its waterprof. lol
 

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Thats smart. I'll figure it out. lol
 

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lol , just unplug everything you can see and jucie it up.
This should be done from factory we wouldnt see so many display flashing posts.Besides this issue i had this quad is bulletproof.
 

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just making sure but you put grease in both fittings? like the male and femaile, so the grease will ooze from the fittings? that'd be frickin messy...
 

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QUOTE ("CDNTRAILEDITION":xnlf8hph)
just making sure but you put grease in both fittings? like the male and femaile, so the grease will ooze from the fittings? that'd be frickin messy...
Yap thats what i did with a cloth you will be all good , just wipe around it when back together and make sure you hear the clip sound it makes when tight .Dont be shy with it .
 
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