Hey there..

Need some help troubleshooting problem here.. Have my Polaris sportsman 400 and all of a sudden the electric start went dead on me?? The pull start works fine still for it? No other issues with the bike other then the electric start going out???I traced back the wiring and no burnt or cut wires anywhere just doesn't want to turn when I push the button???

Was thinking it might be the Solenoid maybe but not sure before I start replacing parts on it???

Thanks

 

first i'd pull the starter and see if it turns over by hand when i pulled the 400 out this year the same thing happened turns out it was just a little rust holding the armature to the magnets ,i cleaned it with emery cloth and it worked fine ever since

 

Itch---

Thanks I'll give that a try... WHat about the iginition key maybe??

 

did you try bypassing the solnoide yet? thats the first place you want to look so you can elimanate that part

 

stendori--

Would I just connect straight to battery then??? Just tried again and now all I get when turn the key is a click click each time, but pull start and cranks fine??????

 

Clicking coming from right by the battery (left side/towards front) actually under the seat??

Is that the solenoid then you think??

 

yup thats the solenoid clicking must be ok, besides i never heard of one actually going bad on these,(although i'm sure it has ) i bet the starter froze up or the starter drive is locked up

 

Thanks...

Had a buddy ask me about the battery might be bad maybe since it was clicking, but said the lights and winch work no problem when I turn the key on....

 

My story for starter removal.


My Manual told me to get special tools and remove primary and secondary clutches to remove back belt housing plate just to make room to remove one remaining bottom starter mounting bolt!

Instead this is what I did. I took out the air box and removed the top easy starter mounting bolt. With the bottom stubborn mounting bolt you just back in off until it hits the backplate of belt housing,it will not come out but will disconnect.
Than I used large channel locks and turned the start clockwise until the bolt was at the 12 O'Clock position and slipped the bolt and the starter right out no problem.

I can,t believe my " Clymer" manual wanted me to tear down half the bike to remove one bolt!

BTW it turned out one of my starter bushes was sticking so I cleaned it up and it works great now. I also put that blue gasket goo everywhere a o ring was, to see if that may help water proof these Polaris starters once and for all.

The brush looked at first glance worn down compared to the second brush ,but it was just stuck in the up position. I used brake cleaner than a lube spay to get it sliding nicely again.

 

I tapped on the started when turing the key and turned over a few times then went ruight back to clicking again like not enough "juice"??

Any chance might be the battery all of a sudden??