Replacing a starter on a POLARIS ATV - Polaris Riders


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Old 08-19-2006, 08:33 PM   #1 (permalink)
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Default Replacing a starter on a POLARIS ATV

just wondering how it's done ?
Replacing a starter on a 2004 sportsman 500 HO POLARIS ATV
i got all the way down to the fly wheel and cluchs but now i'm stuck
hoping somebody here can help me..
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Old 08-19-2006, 10:46 PM   #2 (permalink)
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ANYBODY ?

I need to get this done before next weekend..
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Old 08-20-2006, 08:39 AM   #3 (permalink)
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Where exactly are you stuck?

Rob
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Old 08-20-2006, 01:32 PM   #4 (permalink)
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sorry i'v never done this before..

i'm stuck at the cluches do i need to remove them both or can i just do 1 ?

the resaon i'm taking it out i'm putting in new brushs....
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Old 08-20-2006, 01:36 PM   #5 (permalink)
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I dont' think you have to remove the clutches at all... the starter looks just like a starter on a car, just smaller... it should come out and go back in pretty easily with just a couple of bolts, once you remove enough stuff to get to it.

Rob
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Old 08-20-2006, 02:00 PM   #6 (permalink)
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ok hers what i got from atv posters..
http://atvposters.infopop.cc/eve/forums/a/tpc/f/7331042/m/2781099451

To replace the starter motor you need to remove the clutch cover,drive belt,drive clutch,driven clutch and the inner clutch cover. There are 2 bolts that hold the starter,remove them.Remove positive cable and remove the starter out the left side.




Rob,
the starter sits right behind the cyl. you have to take one or both the cluchs off i'm just trying to find out if i realy need to take both off or not..

ether way i better get buzy on it big ride next weekend..
i'll let you know how it goes tonight..
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Old 08-20-2006, 03:29 PM   #7 (permalink)
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ok now i'm realy having a bad day..

took a puller and thought i could just pull the cluch off well that did't work now i have a broken cluch..

just what does it take to take the main cluch off ??

a cutting torch does come to mind..
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Old 08-20-2006, 04:06 PM   #8 (permalink)
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The right puller is what you need for the primary, have the dealer pop it loose if you don't have any other option. The secondary should slide right off but there is a puller for that also if it's stuck on, then the inner cover will come off after you remove 4 front screws and 3 rear....
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Old 08-20-2006, 11:48 PM   #9 (permalink)
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for the starter(on the twins atleast) you should be able to unbolt the starter, and then knock it out with a rubber mallet(out of the engine sidecase that the starter bendix is in)
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Old 08-21-2006, 03:46 AM   #10 (permalink)
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the 500 may be different than the twins.
I know on the 400 2 stroke it has 2 bolts going into the clutching area.

----------------

Starter removal (actual) 400


1) Securely raise the quad off the floor. I run mine up on 4 car ramps.

2) Remove seat and plastic side panels

3) Remove floorboard to get access to the recoil housing

4) Disconnect battery ground cable

5) Remove pipe. There is only three springs and one bolt and it gives you so much more room to play with. If you can get the Master Link out of the middle chain (I have a 96) do it, it will allow you to easily complete

Step 6 - but it is not necessary
6) Remove recoil housing. I found mine a little stuck so I had to tap it with a rubber mallet. It is still stubborn, remove the airbox and tap it from behind with a stick.

7) Remove the two starter bolts. I could not totally remove my recoil housing, but I shifted it to the right allowing me to gain access to the starter bolts.
Note: I discovered later that I could have removed both middle sprockets & chain to get easier access. (4x4)

8) Remove rock guard from the bottom of the quad

9) Remove starter cable.

10) Use 10mm wrench (long handle would make it easier) to remove the two short bolts attaching the starter support bracket to the engine

11) The starter should then slide out of the recoil housing through the bottom of the frame. Starter Installation (theory)

1) Loosely assemble support bracket to starter. Bracket bolts must be loose as to allow installation of support brackets to engine bolts.
2) Install new gasket (Part 3085283 Ref #18 Grid #D11) and place the starter in place
3) Steps 11-1 above.



--------------------------------------------------------------------------

-Probably the easiest way is by removing the clutches and covers to get at the rear bolts.
-Remove the recoil and the 2 bolts inside and your wire and its off.
-You can take it off without removing the clutches, but its a real pain to put back.
As for what a dealer would charge, its hard to say for the guys around you.
We generally have about $65-75 for pulling it, cleaning, rebuilding, and reassembling + parts.
-Jeff (tech)

ps: don't forget to check the starter drive (bendix), make sure its free in one direction and the spring is still around the weights.
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