1999 Sportsman 500 issue
#1
Got two issues, first is a starting issue, when I try to start it all I get is a click from the seloniod next to the battery. batter is fully charged, is this a bad seloniod, or how do I text to find out? Second is the rear outer cv, works great going forward, but in reverse grinds and snaps, guessing bad joint, was wondering if anyone has had luck with just replacing the bad cv instead of the whole shaft? Thanks for any help on this.
#2
If sure the battery is good,load tested,no cells shorted out,holding a good charge,then you can just use a cheap test light to see if power is getting to starter when you try to crank it. If not,then it's the solenoid.If the solenoid is clicking it's at least getting power from the ignition switch,but may be shorted out internally. If power is getting to the starter then it's a starter or starter bendix problem usually. Just from my experience,you can replace the affected joint, but if the plunging joint goes out(or is really the one making the noise) then it will cost you more to replace them separately than to replace the whole assembly!I've done this a couple times and have been snake bit by replacing one or the other and either still had the other cv still making noise or go out a short time later. Assembly is not cheap,but sooner or later the other one will usually do the same thing,especially if it's the original drive shaft! OPT
#3
To test the solenoid you can jump across the two main posts with a screw driver. If the starter kicks over most likely the solenoid is bad. If the starter still doesn't kick it could be the starter itself. Try tapping on the side of the starter with a hammer then try again. It seems to be an ongoing problem with the starters on polaris. Moisture finds it's way inside and corrodes the brushes and then they stick. You can try pulling it apart, cleaning it up and lube the brushes and channels they sit in with dielectric grease to fix it, or go to DB electric and purchase a new starter if it's to far gone for repair. CV's can be repaired pending on whether or not there is significant damage. I would not let it go for long as the longer it's ridden this way the more damage could be caused.
#4
Thanks guys for the tips and help. One more weird thing I used the pull cord to start it, worked great the went back in the day and the cord would not pull out, after being mad came back and it pulled free, and worked, it has done this to me twice now, any ideas?
#5
Take the recoil cover off. Remove the 10mm bolt on the round plate,lift up slowly,DON'T pull up on the plastic reel as the spring could unwind,lightly grease the underside of the plate where the friction spring is (clip on spring), check that ratchet and ratchet spring work properly,replace plate and tighten bolt. Operate pull start off the atv and see that it works properly. OPT
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KimSJoh
Polaris Ask an Expert! In fond memory of Old Polaris Tech.
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Jul 18, 2015 07:20 PM
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