2005 500 sportsman pull starts and runs fine. Turning the key only produces a single click. Tried jumping the two big red wires on the solenoid, still one big click... it's the solenoid that clicks. I just bought this machine used, knowing it had this problem. I figured it was a dead battery... it hasn't had the new ecm that will be covered by warranty as soon as I can get it in.

any help appreciated.

 

That happen to me, It was the startes's brushes were sticking due to moisture and corrosion,I just took the starter apart and cleaned and lubed the brushes to get them to move free once more. Its a Free fix,take the air box out and remove the starter that way,NOT the manuals direction of removing the clutch dive pulleys.

 

Thanks for the reply...I will start researching starter removal, and get ready to do it.

You're probably right on the money. The starter won't even make a peep, just the click of the solenoid.

The machine only has 950 miles and 126 hours. Maybe it's been through some water, though the owner said no deep water.

Any more guidance appreciated. Hopefully I can get some pics of another removal or some tricks/ torque settings... I don't have a manual.

 

yep, sounds like the starter is stuck. maybe take out for a good cleaning might fix the issue.

 

By the way, the wrench symbol blinks 10 times when I turn the key on. All the instrument cluster symbols and lights seem to work perfectly.

How long should it take to pull the starter off?

 

My Manual told me to get special tools and remove primary and secondary clutches to remove back belt housing plate just to make room to remove one remaining bottom starter mounting bolt!

Instead this is what I did. I took out the air box and removed the top easy starter mounting bolt. With the bottom stubborn mounting bolt you just back in off until it hits the backplate of belt housing,it will not come out but will disconnect.
Than I used large channel locks and turned the start clockwise until the bolt was at the 12 O'Clock position and slipped the bolt and the starter right out no problem.

I can,t believe my " Clymer" manual wanted me to tear down half the bike to remove one bolt!

 

if its an efi version 500 turn the key off and on 3 times leaving it on the 3rd time(this is w/out trying to start it) and it will read codes by counting the blinking flashes of the check engine light.

 

Thanks TLC, that gives me way more idea than I had.

I appreciate all the advice.

It's not a fuel injected model, so will the wrench logo (which I'm assuming is the check engine light) go out on its own? Is it flashing b/c of the bad starter?

 

Before you start tearing things down, try the following:

1. Make sure your connections to battery are clean, tight and corrosion free.
2. You have a good charge on your battery. If your lights are bright and your winch still works your battery is likely strong enough.
3. If you hear a single click when you turn the key over, try jumping the the 2 big red posts on the starter solenoid beside the battery.
4. Try the pull start when key is in run position.
5. Could be your starter is stuck. Try tapping it a little and then turn the key. You should be able to tap the starter with something without removing the air box.

I did all of the above. I was able to tap the top of the starter with a blunt ended object and hammer and it fixed the problem. Put the seat back on and good to go!