anyone else have this problem... when the temp outside goes below 32* the electric start doesnt work, just clicks and its not the battery. Last year i had this problem, took the plug out under the recoil rope and drained a lil water out, we figured water got in where the pull cord sits, so the dealer took the cover off, put a new rope in, and cleaned it out so no moisture was in the recoil/starter case. Now I electrical taped, black taped, and duct taped the pull cord top to make sure no water could get in there when crossing a creek or splashin a puddle. Went to fire 'er up this mornin when it was below 32* last night and nothin, gave a lil tug on the pull cord and it felt like it was solid, worked it a lil bit and it finally came free and pull started it no problem, after that the electric start works fine. Took the plug on the bottom back off and no water came out, the pull cord it a lil damp. I dont know much bout taking the case off to look inside but what do u guys think?

 

I have a 01 Polaris Xpidition 425.I just ran into the same problem the kids were out riding it and the pull starter cord wasn`t down on the plug and I guess water got into it and when the starter would`nt start it I pulled the rope and it got stuck out.It finally went in and took the cover off and cleaned it and Never seezed the hell out of the inside don`t have no problems so far.

 

sounds like you got mostiure down there for sure and it froze. it doesnt take much to make the starter not work. there really isnt much turning power to overcome a little frost.