Any Polaris Sportsman experts??

[landoman]

I have a 2007 Sportsman 500 EFI. Everything has worked fine on it until about January 15th when it did not want to start. Click Click Click. Assumed dead battery so read the label on the battery and charged. Same thing. I pull start it just fine.

Removed the battery and took it into the house as it was below zero thinking maybe something froze. Brought it back out in the morning and it fired right up. Runs all day for fishing, bring it home and park it. Next morning, Click Click Click. nothing. I turn the key on and off a few times and it starts right up.

I take the battery to batteries plus - they test and tell me it is not holding the load as good as it should be. I buy a new one and put it in. Click Click Click. I can pull start it just fine.

I start looking around and it might be the ECM or possibly some loose wires somewhere.

Any other ideas or suggestions would be appreciated. I will be up this weekend and need to plow.

 

[doo_dr]

Starter solenoid, start switch, gear select switch, sticking starter bendix, flat spot on the start motor armorture (spelling???), or just loose and corroded connections. Start with the basics and make sure things are clean and tight. You can be at this for hours so take your time and double check your work as you go along.

 

[wilson]

i'd check and clean the connections at the starter solenoid first,also inspect the connectors themselves for corrosion where the wires are soldered on

 

[jmk62]

put a voltmeter on the battery first thing in the morning and see if the battery is dead..[should see around 12 to 12.5 volts] if the new battery is also dead first thing in the morning you have something drawing the battery dead over night. add on equipment is the usual culprit...if you have none of that each circuit will have to be tested for amp draw on the battery. even a weak [not dead] battery will cause issues with these models. have you tried shutting off the master kill switch on the left handlebar instead of just the key at night? I have seen the polaris ignition switch fail and not completely shut down the system....using the kill switch should eliminate that as a problem

 

[qber]

sounds like starter solenoid

 

[kjp47]

I have the same model, same year, same problem except mine would not restart at all. it would just click 3 times which was the fuel pump starting, the gauge pod would not come on either, in the end the problem was the resistor pack was bad. it is a aluminum box located above the radiator under the headlight, the only way to test it is to remove it or have a dealer remove it and have it tested. if the battery holds a load then this is probably your problem. $250 just for the part.

 

[landoman]

Thanks for all the replies. I started looking at on Sunday. The day before (saturday) I went to start it in my garage and again nothing. I pulled started it just fine and loaded on the truck and went fishing for the day. I started it on the ice no less then 20 times with no issues at all. I did notice on Saturday my handwarmers were not working though...

Sunday we concentrated on the hand warmers. Tested everything and they had power all the way to the actual controller that turns them on/off and up/down in heat. Then nothing. We are looking at replacing them now. They have only been on since late October.

I did go through the connections on solenoid and battery, all snug and no corrosion. There was a little blue on the positive cable to the starter. Took that off and cleaned it up. battery is brand new and tested good sunday.

Other than that, without being able to repeat the issue over and over, it is hard to track down.