Polaris 600 Question

artmart · #1 (**permalink**) 08-04-2007, 07:10 PM

Need some help: I have '03 600 Sportsman, the starter armature burnt out and I replaced the starter. Now all I get is a clicking at the selinoid. I replaced 3 fuses under the shrowd and checked the selinoid, it is good. The battery is brand new and has a full charge. I ran a bench test on the new starter directly off my battery charger and it seems to be spinning. Wires are all good. Any help would be appreciated.

BIGCATDAVE · #2 (**permalink**) 08-04-2007, 07:19 PM

Are you sure your engine isn't locked up? Aside from that, recheck wires and grounds.

Hambone · #3 (**permalink**) 08-04-2007, 10:48 PM

Take the stator cover and try turning the motor by hand. I think Bigcatdave is right your motor may be locked up

artmart · #4 (**permalink**) 08-04-2007, 10:54 PM

I just went down and tried that it, turns with one hand. I'm at a loss. I took the starter back off and placed it in a vice and put the charger to it again and it spins great. The selinoid just keeps clicking. I even tried reversing the wires on the selinoid, it does the same thing. It has to be the selinoid.

BIGCATDAVE · #5 (**permalink**) 08-04-2007, 11:18 PM

Cross the heavy terminals with a screwdriver or something, don't short it to the frame. If the engine jumps, then yeah it is the soleoniod.

artmart · #6 (**permalink**) 08-05-2007, 12:49 AM

jumped the soleoniod terminals and it did nothing.....

BIGCATDAVE · #7 (**permalink**) 08-05-2007, 12:57 AM

can you jump a hot from the battery to the starter? there must be a bad ground on the starer, or a screwy wire.

artmart · #8 (**permalink**) 08-05-2007, 01:06 AM

[I tried a new ground wire from the battery to the starter. I tried hooking the battery charger directly to the starter and through the wire which would have been attached to the soleoniod. The starter turns but the motor won't kick over. The only thing that I can think of is that there is another gear that the starter engages and that gear turns the fly wheel. The gear moves in and out by hand and it will spin by hand but the starter doesn't turn it even with the battery charger hooked directly to the starter. I kept the shroud off when I tried both of these things and it didn't move. This still doesn't explain why I only get a clicking sound from the soleoniod when I turn on the key?? I downloaded a service manual and went through in some detail...I'll have to look again. It was interesting that the starter from the dealer was $300+ and I got a new one on line for $84

BIGCATDAVE · #9 (**permalink**) 08-05-2007, 01:13 AM

OK, You got me stumped. Where are you from?

artmart · #10 (**permalink**) 08-05-2007, 02:06 AM

PA Johnstown