Im having a issue with my solenoid popping. Ive replaced the solenoid (twice cause I thought maybe got a bad one first time) and starter. The battery is fairly new and charged 100%. I have checked all the grounds and cleaned them. I can start it by jumping the solenoid terminals with a screwdriver. And once the bike warms up I can turn it on and off with the key with no problems, but when its cold just popping and have to jump with a scredriver again. Everything works fine when the bike is warm. Any Ideas??

 

What model? Solenoids on the older models were grounded to the side of the battery box.

 

2007 Sportsman 800 I did sand down where the solenoid screws into the frame.

 

Either a connection problem where the solenoid ties into the ignition switch or a battery problem if you're positive on the ground. Have the battery load tested to eliminate it even if it's fairly new. It may show over 12 volts charged,but can drop fast under a load such as starting if it has a dead cell. Gotta have a good solid solenoid ground, good connections to the ignition switch and a good battery.If the battery load tests ok,then I'd trace back wiring to the switch.

 

Just had battery load tested, tested good. Guess I'll start tracing wire. Just not sure what changes when its warm that makes it all work.

 

Grind the area smooth where the solenoid mounts not just the screw holes. Should have two wire connection on this solenoid. Red/white and I think a blue wire. Trace these back to the switch,plus the problem could be in the ignition switch itself or its connector.

 

Went to put the battery back in from the load test and noticed the fluid levels were right at the min. level, so filled them up and recharged the battery. Seems to be working now. It was charging to 12.4 volts at 100% (according to digital readout on charger) now its charghing to 12.9 volts. Im assuming when it was warm the stator was charging the battery enough to restart but was losing charge pretty quickly.One thing I learned for sure just cause you can jump the solenoud with a screwdriver and it starts doesn't necessarily mean the selonoid is bad. Thanks for your input Old Polaris Tech.

 

That can do it. Look over this on batteries. 12.4 volts is actually only 75% charged..https://www.batterystuff.com/blog/ho...ry-is-bad.html