04 sp500 won't start
 

My sportsman won't start with the starter. I hear a clicking coming from the relay just in front of the battery but that is it. Battery is fully charged, first thing I checked. It starts and runs fine with the pull start. Is the relay or selenoid dead or could it be the starter? All lights work and winch is strong. I ran it all day, shut it down and nothing, just " click click". Thanks in advance.

04 sp500 won't start
 

w/ the key on jump the 2 big wires on the solnoide and if it turns over the starter then its bad. it not and you have at least 12.5 volts in the battery then theres a problem w/ the electric starter.

04 sp500 won't start
 

JUST SEARCHED AND FOUND THIS THREAD ABOUT YOUR SPORTSMAN NOT STARTING. i HAVE THE SAME THING GOING ON. WHAT DID YOU END UP DOING.
I AM ABOUT THE REMOVE THE STARTER AND IT LOOKS LIKE A TIGHT FIT FOR THE WRENCHES.
LET ME KNOW WHAT YOU ENDED UP DOING AS FAR AS GETTING THE STARTER TO WORK.
THANKS

04 sp500 won't start
 

did you rule out the solnoide being bad? maybe if you ask "caperinmuskoka" (he has a manual)he will look up the proper removal of the starter for ya.

04 sp500 won't start
 

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 starter 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 had the clicking at the solenoid.

04 sp500 won't start
 

The bottom bolt is pretty tight down there, I'll give that a try. The solnoid is clicking.

04 sp500 won't start
 

Just use a open end wrench ,it will not pull out but will release,then turn the starter to 12 O'Clock and pull it out. Do in reverse order to reasemble. On mine the one bush looked worn out but it was just stuck in the up position.