sometimes went i start up, the starter clicks, grinds and makes noises.

i tested the battery voltage and its 12.8 v.

cleaned the terminals, no help

when i jump the 2 red wires and bypass the solenoid, the same problem occurs.

should i just buy a new starter and replace it, they are only 25 bucks on ebay

 

You can pull the starter and check that it spins freely,but may not be an accurate test as it's not under a load. Also had quite a few idler gears that would either be dirty or had ground down the teeth of the idler gear that contacts the starter causing cranking problems,but usually hear a grinding noise. You might check this area also. May help to eliminate where the problem is.Items 15-21.Dirt Cheap Yamaha & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

so i think you are telling me to remove the cover under the kick starter and see if the gears under there are dirty or worn?

 

Yes,no harm in pulling the cover,plus you'd be surprised how dirty the inside can be.Lot of belt dust that you can blow out,plus while in there you can check the idler gear and if it checks out ok as far as no damage,I'd still clean all parts with spray electrical/carb cleaner. Plus a good time to clean/oil the kick starter as they all get dirty and eventually stick.

 

thx for the tip. i pulled the cover, cleaned it out (wasnt too dirty). belt wasnt worn. kick starter works better now. the solenoid has been clicking more lately. when you bypass it (jump the 2 red wires) it always works. when the solenoid fails it clicks, if you tap it and press the starter it will start. i cleaned the solenoid connection twice. and and cleaned the starter button too. should i just replace the solenoid, they are like 60 bucks.

 

Unless you can find a cheaper relay from a Imported atv that would work,then yes replace it. Sound like it's faulty. here's one on ebay,not any cheaper At Cycle Parts Warehouse either.http://www.ebay.com/itm/POLARIS-SPORTSMAN-90-OEM-STARTER-RELAY-SWITCH-/181297327760?pt=Motorcycles_Parts_Accessories&hash=item2a3629ae90&vxp=mtr

 

do you think this one will work:
http://www.ebay.com/itm/New-Starter-Relay-switch-Suzuki-lt80-eton-kymco-viper-beamer-80cc-90cc-50cc-70cc-/221455477822?pt=Motors_ATV_Parts_Accessories&hash=item338fc66c3e&vxp=mtr

 

A lot of Taiwanese,some Chinese machines parts can interchange,but not every thing. Possible if your connector has the same size plug to fit this relay,it'd probably work. But if if doesn't fit,can't return it for a refund in most cases.Then it just costs more to get the right one.