So i bought a 95 magnum 4x4 that needed its fair share of TLC. I put in a fresh battery, it needed all new lights, changed the oil. I used it a bit during hunting season and the battery would die every couple days. No biggie i would just charge it. Well it got to where it would start bogging down if i gave it gas. Took a look at the rectifier and it looked bad, like it was melting. Swapped that out with a replacement from caltric. Then the bike wouldnt start at all...i had lights, but it wouldnt start. Noticed a clicking coming from around the battery and it was the starter solenoid so i replaced that. Once i replaced that i dont even get lights. And i have tried swapping the cables around on the solenoid. Forgot to mention I cleaned the carb when i first got it and replaced the needle and seat. Also, had the batter load tested and its fine. I have a what looks like a 2nd ground wire coming off the battery that goes to the front of the frame and appears to plug into the terminal board, but i dont know where or even if its been plugged in since i had it.

Thanks for taking the time to read. A bit of help would be greatly appreciated as to figuring this out.

 

Extra ground wire from the battery could have been from a winch install or other auxiliary equipment po might have had. Plus you can check the main ground cable is secure at the lower starter bolt. If you don't have power now,check that the 20 amp circuit breaker in the sealed pouch is getting voltage on each side of the red wire.It's located up from the battery usually tucked under the rear fender.Slice the pouch open if needed to check if the breaker terminals are corroded.You can get this at any auto store.Item #2. http://www.cyclepartswarehouse.com/f...1995&fveh=5400

 

Completely agree with above that it sounds like a faulty/corroded electrical connection. As mentioned, clean the connections or go a step further and also replace the pos/neg cables too.

 

Polaris really did a major improvement in ATVs in 1998. Before that they were shaky coming off the showroom floor.
The good news is, the ATV has you almost trained as a mechanic if you ever need a side job.

 

Well i took a harder look at my at my positive cable from the battery to the solenoid, the wires at the end of both sides were corroding pretty bad. Cut off the bad ends and put on new connectors and the ive got lights and the new solenoid sounds much stronger. Still not starting, but the bike is a 95 and i dont know if the bendix or starter motor has ever been replaced. So thats next. While im here, do you guys know what would be rubbing on the inside of the outside clutch cover. I only hear it rub at idle and it builds up enough heat to melt the clutch cover a bit.

 

The rubbing is the clutch rubbing the cover because the cover is warped. Later they came out with a clutch cover that was bigger and doesn't warp and rub. It has a bigger tube to flow more air.

 

See if you can move the backing plate L bracket out a little which will pull the cover up a tad and see if it stops rubbing. If it doesn't, find a newer bulbous type cover on Ebay as jumbofrank mentioned. Item#26. Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

Well i finally got my recoil starter case off. It was held on pretty good with some type of silicone. Had to heat it up and get a rubber mallet. After i got it off the i saw the teeth on my bendix have been chewed pretty good. My flywheel is also all rusty. Id like to take it out and clean it up a bit. I dont want to damage it though. I may be able to get my hands on an air impact gun. If not though I have pullers similar to this. 4 Piece Three-Jaw Puller Set Would i be able to get the job done with that? If i cant use that, what size bolts might i need for this?

 

NO on the 3 or 4 jaw puller!! This can damage the flywheel and stator! Takes a harmonic balancer puller or a round multi hole puller to remove the flywheel. The three 8mm screw holes in the flywheel are there for a reason. If the metric screws(at least (3) three inch long 8 x 1.25 mm screws) don't come in the kit ,any hardware store will have them,plus you can "borrow" this tool at most auto stores. You can remove the starter bendix by wiggling it around and pulling it out if you don't want to remove the flywheel.

 

Should i be able to turn my flywheel by hand? I was looking at it more closely with a flashlight and noticed a bunch of black pieces in there behind it. Turns out they are magnetic too. Im thinking one of the magnets broke and is possibly jamming it? Either way it looks like Ill be needing a new flywheel as well.