Hey all, been some time since I have had a question. Here's the deal, the 90cc will kick start but the elec start will not work... no clicking, no sounds at all. Here is what I have done so far.

Replaced the starter relay\selanoid
Replaced the starter
Battery is new

I have pulled the thumb switch apart, everything looks good. I have checked the connections to the kill switch, looks good there also. What else can I do? Clearly now I have a short somewhere that I cant find. What would the next step be to try? Black box? fuse I dont know about? Thanks for any help

 

I am currently having this same problem with my 2004 predator 50. I have replaced the starter relay, starter and the battery. I pulled the entire harness looking for a short and everything looks good. Have a CDI on order but not sure if it would cause this problem. Any ideas would be appriciated. Thanks

 

lskylark,

Have you installed your new CDI yet? Did it work? let me know.

 

ok...I found the pull tether saftey switch was bad. I dont know if the 90 has the same saftey swiches. After bypassing the swich i could get the starter to click but still wouldnt turn. I had to pull the clutch cover off the left side of the engine and do a good clean and lube. Works just as it should now. I also found that wd40 makes the belt slip very bad, so i had to spray everything back off with break cleaner and let it sit up for a couple of hours. Might try to jump your starter (put power directly to the starter) and see if its electrical or the starter / engine. If you can get it to turn over or click with the starter installed then your problem is electrical. If the starter doesnt click then try pulling the starter and jump it with it out...see if it actually works. If you have to pull the starter to see if it works then you might want look at pulling the clutch cover. hope this helps and isnt too confusing.

 

lskylark,

Yeah, it has the same saftey swith. How do you bypass that? I know it cant be the starter, relay or battery, those are all new. So it has to be the saftey switch or some wiring someplace

 

I just unplugged the switch and wired the harness side together. All you have to do is complete the cicuit. Another question...does your brake light work? the 50 has a saftey switch that you have to pull the rear (left side) brake handle to be able to start it. If this swich is not working your brake light wont work.

If your brake light works try this before you unplug/rewire anything...ground the green/black wire on the brake light side of the relay (if your wire is not green, then its the wire that goes threw the relay and continues back to the brake light and is connected to the <span class="FTHighlightFont">ground</span ft> portion of the brake light). Just do not ground out the power wire. You can do this by unpluging the harness from the brake light and put a wire to ground into the connector. Now, pull the left brake handle and hit the start button. If it clicks/starts, then your pull tether switch is bad, or you have a bad ground in your harness. This is probly not the best way to check this but...it worked for me.

 

I am having problems with a 2005 predator 90, i took the crank case cover off and removed the small double gear from the starter to the starter gear on the crank. The starter will work great, i think the bearings are froze on the starter wheel on the crank, because it would move at all. You should be able to move it by hand right? I can't move it with a screw driver. Is it pressed on?

 

Hey guys between my brothers and I we have 5 polaris 90's. The starter problems your dealing with are common on these machines. when you pull of the plastic cover on the kick starter side you will see the belt,clutch,and flywheel. If you look closely at the front set you will see a black stamped steel gear at the very back. if you reach in and cannot turn this gear (EASILY) that is your problem. If you are inclined to fix it yourself it is somewhat simple about an hour. For the most part simple tools will do the job, BUT you will need a honda flywheel puller to get back there. I'm working on the part#. After you get to the starter gear you will find it has a (stupid) plastic needle bearing it rides on. The belt dust thats all over your hands gets in it and stops the needles from rolling. We found that electrical spray cleaner that is PLASTIC safe works best to clean it up. WARNING this problem happens at an alarming rate if your rider is agresive or large. Next weekend I will get the performance clutch springs I ordered but it will be about two months before I know if this can stop the problem. After kick starting my son's qaud for a season the manual kick is now sticking.

 

What kind of Honda flywheel puller do I need?

 

Does any body know what size flywheel puller i will need?