I'm fairly handy when it comes to engines...my buddy just bought a Polaris 700 Sportsman Twin. The problem is it turns over incredibly slow. It seems like the compression release (if it has one) is not working or something. Motor barely turns then the solenoid heats up and actually melted the boot on the wire headed to the starter.

I first thought valves need adjusted as that's usually the case when I get these symptoms on other quads, and usually the newer quads have the compression release on the cam. My issue is the valves are hydraulic and can't be adjusted.

Sooo where should I start? I charged the battery to the proper voltage, the starter is good. My first thoughts are the solenoid is shot and the loose inner connection is creating the heat.

Any thoughts?

Thanks In Advance!

 

I agree with you, check all electrical connections. All of them should be "brite and tite".
The problem could also be the wire itself. Be sure there is no corrosion inside the insulation. If it appears damaged this could be it. You can check there resistance if you have a good meter.

Also what is the batt putting out under load? I mean it could have a bad cell and altho reads 12-13V just sitting there. That could drop to 10 or so with a load.

That heat means resistance, I'm still leaning to a connection or bad wire.

CW

 

i doubt it would be the solenoid that is the issue as its just a switch. you can just crss the 2 big cables to see if it still doing it. you sure the starter it self isn't dragging? check voltage when you actually try to start it as well to measure it. imo