Hi!

I bought brand new 2012 -model Polaris Sportsman 500 EFI Base which starter works only occasionally. Especially in cold conditions below minus 18 celsius (0 Fahrenheit) but occasionally problem occurs also in minus 2 Celsius ( 30 Fahrenheit).

Starter relay gives only "klik-klik-klik" -noise when starting. Noise comes from starter relay but also more guiet noise can be heard from starter. Same time "Check engine" is blinking in meter and after stopping starting "Check engine" sign is on about one second. If I put lights on they will not dim which means no extra current is taken from battery.

When you put an extra battery (jumpstart) it will start immediately. Sometimes it starts without extra battery. Battery has been tested and it is good.

Charging voltage is 14,5 volts. After half an hour driving I stopped the engine and after 5 minutes it did not start unless with extra battery.
Local dealer has changed whole wiring and battery but no help.

Beginning of this week I noticed that when problem occurs (starter relay was klicking) I pressed shortly control button of electric winch, the starter started to work!

By the way there is same problem in local dealer's test drive Polaris Sportsman 500 EFI XP!

Seems that either local dealer nor Finnish importer has no glue what could be the problem.

I wonder if anybody has any idea what could be the problem?

 

Welcome to the forum! 2012 500 EFI? You sure it's not a 2011 500efi or 550? Doesn't show a 2012 500 efi in the lineup? Regardless what it is, even though it's brand new can't rule out that you could have a lemon as far as the starter, starter bendix,solenoid? But you say dealer has an XP basically doing the same thing? Plus if you don't keep the battery on a tender might be a good to try this especially during the cold nights. Cold saps a battery's amperage as fast as heat does.Could even be starter control switch problem? Something somewhere doesn't sound right when you can hit the winch control,then the starter will work? Keep us updated. OPT

 

It is 500 EFI 2012.

Starter switch has been changed, too.

I think the problem is inside ECU box. Somehow it is sensitive for voltage level and it varies during temperature change. I'm waiting a new ECU box to be changed.

 

If you replace the ecu it has to be programmed to the atv by the dealer on Polaris Digital Wrench soft ware. If the dealer has narrowed it down to this hopefully this will solve your problem. Good luck OPT