My father in law has the 04 ATP 500.
It will not start with the key. Starts fine with the pull rope.
Local shop here in Idaho Falls told him it was the starter solenoid, so we replaced that last night.
I believe it is the key switch, It just doesn't feel right, It feels squishy and doesn't have that resistance when you turn it to start position.
got full power to the pod, all the lights and everything work....

So my question is two part,
Should I be looking at something besides the switch?
and do we dare use it over the weekend using the pull start?

Thanks in advance
Mike.

 

Common problem with the 500. Can pull start,but won't electric start.If you rule out a key switch, usually one of three things. A dirty or weak pick up coil or the coil gap out of range of the flywheel. Check resistance at the white and white/red wires leading to the cdi. Pick up should ohm out at 97 ohms. If it ohms out ok,then remove the recoil hosing,check the face of the pick up coil and flywheel for dirt or trash plus gap between the pick up coil and flywheel tab should be between .016-.040 per the manual. You may just have to gently "tap" the coil bracket inward a tad and it may have enough spark that the electric start will work. Plus look at this post. If a rope ever breaks the coil can be knocked out of alignment also. no spark to plug when using electric starter - Page 3 - ATVConnection.com ATV Enthusiast Community

 

It does nothing when you turn the key to the start position, And it just doesn't feel right.
I noticed again today that I had to wiggle the key a bit to get power while in the run position, and it seemed to take longer than it should to power down when switched to off.
The local dealer doesn't have one in stock so we are going to look online and see if we can save a couple $$.
He did say to make sure and get the right switch because of a change mid production year. Different switch for anything after July 03 production run.
can I tell that from the vin?

Could I possibly be dealing with a grounding issue?

I will check the things you mentioned when we get to our hunting camp,
but I'm afraid the old man just might have to toughen up his arm.

 

Yes you'll need either #4012164 or #4012165 depending on build date. Nether one are cheap.Item#26. Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse

 

Thanks OPT the switch from your link was 30$ less than the local dealer.

Wasn't able to get one before our hunting trip, The machine worked fine with just the pull start.