how to : Polaris Sportsman remove starter - pics - Page 2 - Polaris ATV Forum
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post #11 of 27 (permalink) Old 08-27-2012, 06:04 AM
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Quote:
Originally Posted by xenon View Post
We just did the same thing on our 2007 500. starter from DB electric rebuilders, also replaced the bendix ($25).

Ours was not a X2, the bottom screw was a booger, just enough room , the head hits the back of the cover behind the clutch assembly. had to use ong needlenose and wrench, turning aobut 1/4 turn at a time.

the bottom screw is tricky, but it can be done.
My bottom screw on my 500 is just sitting there not screwed in.. I could not get it to thread in... so hopfully the top screw is enough to hold it in... the bike is not ridden aggressively so I am not too worried about it...

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post #12 of 27 (permalink) Old 08-27-2012, 06:23 AM Thread Starter
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Place a flathead behind the head of the bottom screw and apply some pressure in while turning the wrench , it will thread back in.


And as for the guy with the problem starting. You wont really know whats wrong till you get everything apart. When you take the recoil housing off you will be able to diagnose both your pull start and your bendix ( = starter drive)
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post #13 of 27 (permalink) Old 08-27-2012, 03:35 PM
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Quote:
Originally Posted by dog812 View Post
Place a flathead behind the head of the bottom screw and apply some pressure in while turning the wrench , it will thread back in.


And as for the guy with the problem starting. You wont really know whats wrong till you get everything apart. When you take the recoil housing off you will be able to diagnose both your pull start and your bendix ( = starter drive)
The starter drive is different from the bendix...right? I was going to go with this combo right here...

DB Electrical - STARTER DRIVE Combo POLARIS ATV 325 335 425 500 PA102 COMBO SMU0061K 18645

I was going to assume that I had the same problem as you, or at least it make sense to me that I did from your posts. The bendix is the part that you should of replaced with the starter the first time right? I'm going to replace both when I tear it down, but what are your thoughts?

My particular situation, if the bendix is malfunctioning, then isn't it plausible that it's why the pull-start won't make a compression stroke? The 4-wheeler ran fine right up till it quit starting from the pull-start. Previously, the battery had sat in storage, but it started first try. By the end of the weekend it wouldn't start under the electric start. I used the pull-start till the end of the day (Sunday), got it home, and used the pull-start to get it off the trailer. The next morning, I went to put it up, and the pull-start went limp after the first pull. By limp, I mean it will recoil, but would not make a compression stroke. When I put the new battery in it had the same exact behavior as it did when it wouldn't start before I started to use the pull-start. I even hit the side of the pull case with a rubber mallet as per a thread out here, but it was to no avail.

Now I'm starting to think that the reason some need to hit the pull-start side is, because of the bendix malfunctioning, or ready to fail...

I thought I had a grip on this situation, what do y'all think? Am I wrong on with what I'm assuming?

I prefer my cars and bourbon from Kentucky. ~Me
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post #14 of 27 (permalink) Old 08-27-2012, 03:57 PM
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Bendix is a brand name for a starter drive, like mentioned above.

Quote:
Originally Posted by ItODDospeed View Post
Quote:
Originally Posted by dog812 View Post
Place a flathead behind the head of the bottom screw and apply some pressure in while turning the wrench , it will thread back in.


And as for the guy with the problem starting. You wont really know whats wrong till you get everything apart. When you take the recoil housing off you will be able to diagnose both your pull start and your bendix ( = starter drive)
The starter drive is different from the bendix...right? I was going to go with this combo right here...

DB Electrical - STARTER DRIVE Combo POLARIS ATV 325 335 425 500 PA102 COMBO SMU0061K 18645

I was going to assume that I had the same problem as you, or at least it make sense to me that I did from your posts. The bendix is the part that you should of replaced with the starter the first time right? I'm going to replace both when I tear it down, but what are your thoughts?

My particular situation, if the bendix is malfunctioning, then isn't it plausible that it's why the pull-start won't make a compression stroke? The 4-wheeler ran fine right up till it quit starting from the pull-start. Previously, the battery had sat in storage, but it started first try. By the end of the weekend it wouldn't start under the electric start. I used the pull-start till the end of the day (Sunday), got it home, and used the pull-start to get it off the trailer. The next morning, I went to put it up, and the pull-start went limp after the first pull. By limp, I mean it will recoil, but would not make a compression stroke. When I put the new battery in it had the same exact behavior as it did when it wouldn't start before I started to use the pull-start. I even hit the side of the pull case with a rubber mallet as per a thread out here, but it was to no avail.

Now I'm starting to think that the reason some need to hit the pull-start side is, because of the bendix malfunctioning, or ready to fail...

I thought I had a grip on this situation, what do y'all think? Am I wrong on with what I'm assuming?

Thanks,
Will

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post #15 of 27 (permalink) Old 08-27-2012, 04:27 PM Thread Starter
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Yeah that is the correct combo..
you might want to take your recoil housing off first , make sure your starter drive / bendix actually needs replacing. Literally takes 5 mins..
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post #16 of 27 (permalink) Old 08-27-2012, 04:35 PM
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dog812, take the recoil housing off first and check what first? That that piece (the other part in the combo that I showed? Moreover, what is that part called?) is functioning properly? How do I check my starter drive?

I'm really new to this, so thank you for everyone's patience, and help.

I prefer my cars and bourbon from Kentucky. ~Me
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post #17 of 27 (permalink) Old 08-27-2012, 04:41 PM
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This is a great post with pictures, thanks all!
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post #18 of 27 (permalink) Old 08-27-2012, 04:45 PM Thread Starter
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Quote:
Originally Posted by ItODDospeed View Post
dog812, take the recoil housing off first and check what first? That that piece (the other part in the combo that I showed? Moreover, what is that part called?) is functioning properly? How do I check my starter drive?

I'm really new to this, so thank you for everyone's patience, and help.
you will see in my latest pics on this thread, the picture of the bendix or starter drive, whatever you want to call it.
It sits just on top of the fly wheel basically.. as soon as you open the recoil housing, it will basically be the only other thing in there.
It will just come out, no tools. Make sure its extending and retracting. Mine, as you can see from the picture, was stuck in the extended position..
The recoil housing removed. You can see where the bendix sits right above the flywheel. You can see the little indent where the end sits.

Bendix 's


Basically your starter turns, the motion causes the starter drive to extend, the teeth grab the flywheel , turns it and starts the bike. Then when you turn the key back, the starter stops and the starter drive should retract back so its not touching the flywheel anymore. Or what happened in my case, it did not retract and was spinning as fast as the flywheel was spinning, which was too fast for the starter and burnt it out.

Last edited by dog812; 08-27-2012 at 04:49 PM.
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post #19 of 27 (permalink) Old 08-27-2012, 05:24 PM
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bendix = starter drive (on the flywheel)
starter = starter

That threw me for a loop.

I firmly believe that what happened to you is what has happened to me. My bendix was not releasing immediately and burnt my starter out. The sound it made when I started it was always a horrible sound on the flywheel side. I will look at the bendix first, take some pics, and get back out here. I want to order the parts now, but I will wait until I see the bendix. I will have to wait till the start of next week one way or another, because...

I am currently waiting for a new coil-pack on a street bike, so I have to wait a few days. Moreover, one of my plug wires has to be ordered from Japan. Yeah! I have a garage stall for all my motorcycles, and have a method to my madness for tear down. I only have so much space that I'm afraid of getting the two bikes confused one way or another. Like I said, limited DIY capabilities.

Thanks for the help dog!

I prefer my cars and bourbon from Kentucky. ~Me
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post #20 of 27 (permalink) Old 09-30-2012, 07:26 PM
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stripped starter bolt

i replcaed the bendix in my 2006 sportsman and had some problems while trying to take off the starter. the bolt that will not back out all the way has becomed stripped to some degree because i messed up. any idea how to get that bolt out given the circumstances?
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