Well I was loading up to head out for the first ride in about 2 weeks. When I turn the key I hear a click from the solenoid (next to the battery) and nothing from the starter. A couple of times this passed week when I moved it all I got was a wine from the starter but when it didn't start, I tried an old Chevy trick and just tapped it to disengage the gear so it would engage the flywheel which worked and it started no problem. I guess its a good thing it happened while at home but its put a damper on the weekend for sure. Is it a starter? or something else? is there a cheat fix other than R&R to get me through the weekend? I will be shopping for a new or rebuilt starter while waiting for an answer. TIA

 

Test light or meter on starter wire when you try to crank it.If it has voltage then it's the starter. If it doesn't could be the solenoid or battery.Plus you can jump the solenoid connections to see if the starter cranks over. Plus don't over look the battery.Load test if need be. Since you've had to tap on the starter before to get it to operate,probably the brushes/armature dirty or worn.Here's a cheap place to get one,plus I'd go ahead and replace the starter bendix. #52 for both.DB Electrical - STARTER DRIVE Combo POLARIS ATV 325 335 425 500 PA102 COMBO or $111 for the pair with a 2 year warranty. Plus plenty on ebay along with the solenoid.http://www.ebay.com/itm/NEW-Starter-Drive-COMBO-Polaris-SPORTSMAN-335-400-450-500-ATV-1996-2012-/360446773655?hash=item53ec4d4997&vxp=mtr http://www.ebay.com/itm/US-Starter-Relay-Solenoid-ATV-For-POLARIS-ATV-SPORTSMAN-500-PSE-HO-02-499cc-/181706101471?hash=item2a4e8712df&vxp=mtr

 

I had something like that, It turned out to be a dirty sticking brush in the starter. I took the starter apart and cleaned the brush and its been good for 5 years now.

 

While trying to research this problem online, I watched some videos on youtube. I took my test meter and saw I have 12.56v off the battery directly. Then I tested the solenoid by doing this: negative test lead to ground on the starter and positive test lead to ignition switch side of solenoid and turned the key. I got 0.02v. I am thinking that if the solenoid was good, when I turned the key, I should have 12.56v going to the starter rather than just 1 click. I then watched this video: and it seems as though (even its hard to watch this guy) he had the same problem and R&R'd the solenoid for his fix. Please advise if I am on the right path. Thanks.

 

OK well here is the update. I am tired of chasing problems and I know if I had a pull starter I would have been ready to go today even without electric start. SO....I went to ebay and ordered: Starter, Bendix, Pull Cord Repair Kit, Trigger Coil, and a Starter Relay. I figure while I'm in there I may as well replace the bendix, pull cord and coil and only replace the gasket once. And for the $8 weather its the relay or not, why stop there. I think its the starter though because I jumped both terminals of the relay and when it sparked the starter did not engage and for the passed few days it has just been whining. Oh well. Now when this is complete, I wont have to worry about water getting into the housing where the stator/flywheel is and I know the ignition system is basically all new. LOL I WILL FIX THIS CRAP ONE WAY OR ANOTHER!!! Thanks for the help and I will post the progress as I get it completed.

 

The whining can also just be the starter and bendix spinning if the bendix garter spring is weak. The starter motor will just spin along with the bendix in unison and at times the bendix can't kick out strong enough to engage the flywheel.Found that to happen plenty of times.Plus can do the same thing(spin in unison) if the starter itself is weak and can't torque the bendix fast enough. That's why it's best to replace both the starter and bendix at the same time like you're doing because both have about the same amount of wear and tear on them. Always good to have the back up recoil starter also,never know when you might need it! Trigger coil and solenoid as cheap as they are online now,why not,I'd get em too.. Keep the old ones for a back up if they're good. Sounds like you have all your bases covered as they say..

 

OPT, once again you guided me in the right direction. I just figure I have to replace the pull rope and it comes with 1 gasket. while I'm in there I may as well replace all the other crap. then of course the starter and the solenoid.I guess my dad's saying is true, if you have a problem and throw enough money at it, I'm sure it'll be fixed. lol

 

Throwing money at things works most of the time if you throw enough,but in the case of my sons 11 year old Cub Cadet mower with a Kawasaki engine,worked out a little different.I replaced his crank shaft about 5 years back when he hit a curb with the blade and bent it.Ran good for 5 years and then just quit. Found it had a blown head gasket and the new one was redesigned to stop this.We cleaned the cylinder and head,new gasket,replaced carb needle,adjusted valves,new air filter.Has good compression by the manual,spark,fuel,valves set properly,no sheared keys,but still won't run. Yesterday he went to Lowes and got a new Husqvarna with a Honda engine.. Sometimes you need to walk away from old beaters,especially lawn mowers..

 

I agree and money will only go so far when you have so many expensive hobbies with limited income. I think I can overcome this one especially with your help. thanks again and I'll keep you posted.

 

Here I am about a week later and I receive the parts that I ordered over the Internet. After finally tearing into the machine, I've decided that be so annoyed and the trigger coil do not have to be replaced so I will keep them on a shelf in case I need them in the future. However, the pull starter repair kit went in flawlessly, the Bendix apparently was on its way out because it did not work smoothly and needed assistance to retract, and the starter was completely seized. now it seems to start with just a bump of the key. The new starter sounds like one of my old race car high torque starters. if you would like to see pictures during the repair go to www.flickr.com/photos/nobleeagle68/sets/72157651689124551. Like always OTP, I thank you very much for your guidance in getting my issue corrected. Stay safe! Until next time...