2005 Polaris Sportsman 400/500 Service Manual, Page 297Get this manual
ELECTRICAL
STARTER SYSTEM TROUBLESHOOTING
Starter Motor Does Not Turn
GBattery dischargedLow specific gravity GLoose or faulty battery cables or corroded connections (see Voltage Drop Tests) GRelated wiring loose, disconnected, or corroded GPoor ground connections at battery cable, starter motor or starter solenoid (see Voltage Drop Tests) GFaulty key switch GFaulty kill switch GFaulty starter solenoid or starter motorGEngine problemseized or binding (Can engine be rotated easily with recoil starter?)
drop tests on the starter systemVoltage should not exceed .1 DC volts per connection
STARTER MOTOR DISASSEMBLY
NOTE: Use only electrical contact cleaner to clean starter motor partsSome solvents may leave residue or damage internal parts and insulation1Note the alignment marks on both ends of the starter motor casingThese marks must align during reassembly