I have a 2003 Sportsman 500 HO 6x6 that doesn't start. It has been running ok but now when I turn the key it does not turn over. The lights work but no power is getting to the starting solenoid. In the users manual it recommends to reset the breaker, does any one know where the breaker is located? Are there any fuses to look at?

Thanks Mark

 

Polaris uses a breaker system instead of fuses - usually the breaker is located in an in line "pouch" on the positive wire coming off the solenoid to the ignition switch. I have always been under the impression that the breakers were thermal and reset themselves once they cooled down.

Since you have lights, the breaker shouldn't be your problem. The brushes may have gotten stuck or gone out on your starter - check to see if the solenoid "clicks" when the key is turned.

 

Check that you have at least 12 volts at the battery, at least 13.5 when running a few rpm's above idle, clean and check all connections at battery and selenoid, check the nuts behind the battery cables on the selenoid too.

 

Thanks for the responses, the solenoid does not click when I turn the key to start. So I by-passed the key and connected 12v directly to the solenoid, where the wire comes from the key. The bike turned over and started ok. So I suppose I can assume that there is a break in the wiring between the key and the solenoid or the power source to the key. I have found a wiring diagram from a 2002 Sportsman 500, I think it should be the same as the 2003 6x6. The power source for the key looks as if it comes from the left handlebar switch assembly - wire marked "d" from the lights switch which in turn gets it from the wire marked either "c" or "d" of the off/on/off switch and this is fed from the 20amp circuit breaker. Can any one confirm if I am reading this correctly?