2000 Polaris xplorer starter cranks but does not start, starts great with pull start

[Cj Winds]

I have a 2000 Polaris Xplorer with the 250 two stroke motor

It does not want to start with the electric start, the motor cranks fast, the battery is good, and there is good spark when cranking. The engine starts perfect when using the pull cord, it even starts if I pull the cord slowly and starts with one pull. The engine idles smoothly once started. My wife says she needs the electric start to work.

 

[davefrombc]

You'll  have to  trace out the wiring on it . There  is a safety switch  or relay not working in the ignition  circuit.  I  would guess  most likely  a relay or possible broken wire  since  it  turns over  on the starter.  Usually  when safety  switches  fail  the  starter  also will  not  spin.  It is not  getting  power to run  when the  start  relay is energized  so  start there  after  checking for an  obvious broken wire.

[Frank Angerano]

So your saying that if you pull the spark plug out and crank the engine with the start button you have spark ? 
Fuel is good ? If so then this makes no sense. Is it an oil injected engine or pre mixed ? 
 

[Cj Winds]

Yes, it sparks using spark tester when cranking the motor. 

[Cj Winds]

Yes, its oil injected

[Frank Angerano]

What do you mean a spark tester ? Did you go the conventional route and put the spark plug on the wire and hold it against the cylinder head and crank the engine to see a good blue spark ? 
 

[Cj Winds]

I put a OTC spark tester on the spark plug lead and had good blue spark, then I used my adjustable spark tester and found the electric start would produce a max of 1/4 spark jump, the pull cord would max at 3/8 jump. Then I installed a new spark plug non resister type and lowered the gap to 0.020 and it still would not run with electric start but still starts fine with pull cord.

[Cj Winds]

I replace the just the bendix gear for the starter motor and now it starts right up, i guess it wasn't turning over as fast as it should

[Frank Angerano]

Ok so the starter was not spinning fast enough. Good find and glad it worked out.