Hey just bought an 05 Polaris Sportsman 800 and I gave it a bath after a long day of muddy trails. During the spraying I kept it running and it started kicking the starter over. then it died and now won't start with the key, yet jumping the solenoid cranks the starter and it runs fine. When I try to start it with the key the solenoid clicks the relay but nothing more. Somethings stopping it from cranking the starter. Its a minor inconvenience to have to lay a screwdriver across the contacts to start it but I'd really like to get it back to the norm. Thanks in advance for your help!

 

Sounds like you need to pull all the connectors and blow them out with compressed air from the ignition switch all the way back to the battery/solenoid connections.. Plus a little electrical grease in the rubber electrical boots and connectors can go a long way on keeping this from happening again.

 

Could it be a killswitch? I have no idea where it is on mine. I'll check the manual in one moment.

 

It can be anywhere since you washed it up! The ignition switch harness connector may be shorting out from water,or the switch contacts themselves may not be sending power to the small solenoid wire which triggers it to send power to the starter,could be the solenoid connections,connections under the front panel,etc. That's why I said to start at the ignition switch first,then check every electrical connection and clean and use dielectric grease to help waterproof. Water can do some strange things on electrical parts.

 

WEll its got power. ran the diagnostics and everything is optimal there. Checked all connections, don't seem to be any faults there and can't find anything on a killswitch in the manual. It does mention a breaker, not sure where that is. Will search the web for a wiring diagram.

 

The circuit breakers and the relays are under the front panel. A 20 amp chassis fuse. Since you have power this one is ok, a second 20 amp fuse for accessories,15 fuse for the injection system, 5 amp for the speedo,plus two relays up from the fuse block. Just make sure all connection are dry. Download this 2009 800 pdf manual. Electronics should be similar for you to check out. PartShark.com - Motorcycle Parts, ATV Parts, UTV Parts, PWC Parts, Powersports Apparel, Motorcycle Accessories for OEM and Aftermarket.