Solenoid Can Am Outlander 500-Replacement and Troubleshooting Tips

You hop on your Can-Am Outlander 500, ready to hit the trails. You turn the key, press the start button, and… click. Just a single, heartbreaking click, followed by silence. We’ve all been there. That sound is the universal signal of a day of riding that’s over before it even began.

I promise you, that frustrating click doesn’t have to mean an expensive trip to the dealership. More often than not, the culprit is a small but mighty component: the starter solenoid. And the good news? You can absolutely test and replace it yourself.

This comprehensive solenoid can am outlander 500 guide will walk you through everything. We’ll cover what this part does, how to spot the common problems, the exact steps to test it, and how to replace it safely. Let’s get your Outlander roaring back to life.

What Exactly is a Starter Solenoid and Why Does it Matter?

Think of your starter solenoid as the tough middleman in your ATV’s starting system. Your start button and ignition switch use a very small amount of electrical current, which isn’t nearly enough to turn over a big engine.

The solenoid is essentially a heavy-duty electromagnetic switch. When you press the start button, that small current energizes an electromagnet inside the solenoid. This magnet does two things at once:

It closes a high-power circuit, allowing the massive surge of amperage from your battery to flow directly to the starter motor.
On many starters, it also physically pushes a small gear (the Bendix) forward to engage with the engine’s flywheel, turning it over.

Without a working solenoid, that powerful connection is never made, and your starter motor never gets the juice it needs. Understanding the benefits of a solenoid can am outlander 500 that’s in top shape is simple: it means reliable starting, every single time.

The Two Main Jobs of Your Outlander’s Solenoid

To put it simply, it’s a gatekeeper for power. Its primary roles are:

Switching High Current: It safely handles the high amperage required by the starter, protecting your more delicate ignition switch from getting fried.
Engaging the Starter: It ensures the starter motor’s gear properly meshes with the engine to initiate the cranking process.

Telltale Signs: Common Problems with a Solenoid Can Am Outlander 500

Your ATV is usually pretty good at telling you what’s wrong, as long as you know how to listen. A failing solenoid has a few classic symptoms that are hard to miss. If you’re experiencing any of these, this component should be at the top of your suspect list.

The Infamous “Single Click”

This is the number one sign. You press the start button, you hear one solid “thunk” or “click” from under the seat or near the engine, but the engine doesn’t crank. This sound is often the solenoid trying to engage but failing to send power across to the starter motor.

Rapid, Machine-Gun Clicking

If you hear a fast-paced “click-click-click-click” when you hold the start button, this can be a bit tricky. It often points to a weak or dead battery that doesn’t have enough power to fully engage the solenoid. However, it can also be a sign of a solenoid with burnt internal contacts that is struggling to make a solid connection.

Pro Tip: Before blaming the solenoid, always test your battery first! A simple voltage check with a multimeter can save you a lot of time and money. A healthy, fully charged battery should read around 12.6 volts or higher.

Complete Silence

You press the button and get nothing at all. No click, no crank, nothing. Assuming your battery is good and your dash lights come on, this could mean the solenoid’s internal coil has failed completely and isn’t even trying to engage anymore.

Starter Motor Won’t Disengage

This is a less common but more serious problem. If you start your Outlander and the starter motor continues to run even after you release the button, shut the engine off immediately! This means the solenoid’s internal switch is fused or stuck in the “on” position, which can quickly destroy your starter motor.

Your DIY Toolkit: Gear Up for the Job

Before you dive in, let’s get your tools and safety gear in order. Having everything ready makes the job smoother and safer. This isn’t a complex task, but preparation is key to success.

Essential Tools

Socket Set and Wrenches: You’ll likely need 8mm, 10mm, and 12mm sockets or wrenches for the battery terminals, solenoid mounting bolts, and cable nuts.
Multimeter: This is your best friend for diagnosis. You don’t need a fancy one; a basic digital multimeter will do the job perfectly.
Safety Glasses: Non-negotiable. You’re working with a battery and electrical components. Protect your eyes.
Gloves: Mechanic’s gloves will keep your hands clean and protect them from scrapes.
Wire Brush: Excellent for cleaning corrosion off battery terminals and cable ends.

The Most Important Step: Safety First

I cannot stress this enough. Before you touch a single wire or bolt, you MUST disconnect the battery. Always disconnect the negative (black) terminal first, then the positive (red) terminal. This prevents any accidental short circuits that could damage your electrical system or cause injury.

The Definitive Solenoid Can Am Outlander 500 Guide: Testing and Diagnosis

Alright, let’s get our hands dirty and figure out if that solenoid is truly the problem. Follow these steps carefully. This is how to solenoid can am outlander 500 diagnosis is done right.

Step 1: Locate the Solenoid

On most Can-Am Outlander 500 models, the starter solenoid is located under the seat, near the battery. It’s a small cylindrical or square component with two large posts (for the heavy-gauge battery cables) and one or two smaller wires connected via a plastic plug.

Step 2: The Multimeter Test (The Safe Method)

This is the professional way to confirm a bad solenoid. Set your multimeter to DC Volts (V–).

Confirm Power TO the Solenoid: With the battery connected, place the red probe of your multimeter on the large post where the cable from the battery’s positive terminal connects. Place the black probe on the battery’s negative terminal or a clean frame ground. You should see battery voltage (around 12.6V). If not, you have a problem with the cable from the battery.
Check the Trigger Signal: Locate the small wire(s) going to the solenoid. Have a friend turn the key on and press the start button while you carefully touch your multimeter’s red probe to the trigger wire’s terminal and the black probe to a ground. You should see ~12V when the button is pressed. If you don’t, the problem is in your switch, wiring, or fuse—not the solenoid.
Check Power OUT of the Solenoid: If the first two tests pass, this is the final check. Keep the black probe on a ground. Place the red probe on the other large post—the one with the cable going to the starter motor. Have your friend press the start button. If you hear the “click” but see little to no voltage on this post, you’ve found your culprit. The solenoid is not sending power through. The solenoid is bad.

Step 3: The “Bypass” Test (Use Extreme Caution)

Disclaimer: This test can create a large spark and should only be performed by those comfortable working with live electrical systems. Wear safety glasses.

This test, often called the “screwdriver trick,” bypasses the solenoid entirely to see if the starter motor itself works. With the ATV in neutral, place the metal shaft of an old, insulated screwdriver across the two large posts on the solenoid. This will complete the circuit manually.

If the engine cranks over strongly, it confirms your battery and starter motor are good, and the solenoid is 100% the problem. If nothing happens, your issue lies with the starter motor or its connections.

Step-by-Step Replacement: A Fresh Start for Your Outlander

Once you’ve confirmed the solenoid is dead, replacement is straightforward. Here’s a simple, step-by-step process.

DISCONNECT THE BATTERY: I know I’ve said it before, but it’s the most critical step. Negative terminal first.
Take a Picture: Use your phone to take a clear picture of the wiring on the old solenoid. This is one of the most valuable solenoid can am outlander 500 tips I can give. It eliminates any guesswork during reassembly.
Disconnect Wires: Unplug the small trigger wire connector. Then, use your wrench to remove the nuts holding the two large cables on their posts.
Unbolt the Old Solenoid: Remove the bolts or screws holding the solenoid bracket to the ATV’s frame. The old unit is now free.
Install the New Solenoid: Bolt the new solenoid into the same location. Make sure it’s secure.
Reconnect Wires: Refer to your photo! Re-attach the large cable from the starter and the large cable from the battery to their correct posts and tighten the nuts snugly. Do not overtighten. Reconnect the small trigger wire plug.
Reconnect the Battery: Connect the positive (red) terminal first, then the negative (black) terminal last. Ensure they are tight.
Test Your Work: Turn the key, hold your breath, and hit the start button. Your Outlander should roar to life!

Solenoid Can Am Outlander 500 Best Practices and Care Guide

To ensure your new solenoid lives a long and happy life, a little preventative care goes a long way. This is your solenoid can am outlander 500 care guide for long-term reliability.

Always choose a quality replacement part. While cheap options are tempting, an OEM or reputable aftermarket solenoid will have better internal components that last longer. This is also the core of a sustainable solenoid can am outlander 500 strategy—buy a quality part once instead of cheap parts three times.

Keep your battery terminals and all cable connections clean and tight. Corrosion creates resistance, which makes the solenoid and starter work harder. A healthy, fully charged battery is also crucial, as low voltage is tough on electrical components.

When you dispose of your old solenoid, be responsible. This is an eco-friendly solenoid can am outlander 500 practice. Don’t just toss it in the trash. Most auto parts stores have recycling programs, or you can take it to a local scrap metal or e-waste facility.

Frequently Asked Questions About the Solenoid Can Am Outlander 500

Can a weak battery act like a bad solenoid?

Absolutely. A battery with low voltage can cause the solenoid to chatter or click rapidly because it doesn’t have enough power to hold the internal switch closed. Always test your battery before replacing other parts.

How much does a new starter solenoid for a Can-Am Outlander 500 cost?

Prices vary, but you can typically expect to pay anywhere from $20 for a basic aftermarket solenoid to over $60 for an OEM (Original Equipment Manufacturer) part. For a component this critical, investing in a quality part is often worth the extra money.

Is this a difficult job for a beginner DIYer?

On a scale of 1 to 10, this job is about a 3. The most important part is being safe and methodical with the battery disconnection and wiring. If you can use a wrench and a multimeter, you can do this job.

Fixing your own machine is one of the most rewarding parts of being an off-road enthusiast. By following this guide, you’ve not only saved money but also gained valuable experience and a deeper understanding of your Outlander. Now, get those connections tight, double-check your work, and get back on the trail!

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Thomas Corle

Founder & Automobile expert at FatBoysOffroad

Automobile expert and off-road enthusiast, sharing in-depth knowledge of vehicles, gear, and adventures. Helping readers make smart decisions and enjoy the thrill of off-roading safely and confidently.