Can anyone give my any tips for rebuilding the starter on my 04.5. It has been hanging just a little when starting and today it wouldn't engage at all and just spins. How easy is it to get out and are there any rebuild kits out there or should I just piece it toghther and see what it needs?

 

RICK'S MOTORSPORT ELECTRICS ANNOUNCES NEW STARTER MOTORS AND DRIVES FOR THE '02 - '04 POLARIS SPORTSMAN'S

Rick’s Motorsport Electrics introduces brand new starter motors and starter drives for the 2002-2004 Polaris Sportsman 700. The new starters are a better, more effective design at a lower cost than an O.E. replacement.
Rick’s Motorsport Electrics’ starter features a ball bearing on the drive end instead of the O.E. style needle bearing. What’s the bid deal? When the O.E. needle bearing fails, as often happens, it also renders the armature and entire starter motor unusable.
Rick’s new design eliminates this problem. “We’re proud to offer a stronger, heavier duty design at a lower cost to our customers,” says company president Richard Shaw. “And we will continue to offer quality replacement pieces at a significant cost savings for the customer.”
The new starter motors and starter drives come with a one-year warranty. They are available directly from Rick’s Motorsport Electrics and their distributors. Starter motor, part #61-506, has a suggested list of $200. The drive, part #61-503, has a suggested list of $130. These pieces are brand new, so there is no core exchange required.
For more information on these and other products from Rick's Motorsport Electrics, please visit their website at www.ricksmotorsportelectrics.com or call them at 1-800-521-0277. Rick’s specializes in the charging and starting components for street bikes and off road/ATVs. Rick’s Motorsport Electrics will continue to deliver The Right Product, The Right Fit, The Right Price.

 

http://www.mfgsupply.com/m/c/process.html

Part # Description OEM # Sug. Retail Our Cost
SMU0034 Polaris ATV Starter: Polaris 85-01 250, 300, 350 & 400 models 3085393, 3084403 $306.99 $104.95 Purchase

SMU0061 Polaris ATV Starter: All 325 Magnum 4 stroke, all 335 Magnum 4 stroke, 95-02 425 Magnum 4 stroke & all 500 4 stroke $306.99 $104.95 Purchase

SMU5003 Polaris ATV Starter Drive 3085394 $155.00 $49.95 Purchase SMU9115
Polaris Brush Repair Kit: 2 Brush Models $60.00 $39.99 Purchase

SMU9116 Polaris Brush Repair Kit: 4 Brush Models $60.00 $49.99 Purchase

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P.O. Box 167
Dorchester, WI 54425
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1-800-294-4144

 

Does anyone know if I can get just the drive gear itself rather than the whole assembly as that is the only part I really need. The Polaris parts catalog doesn't show it by itself you have to get the whole works.

 

Dude, i had the same prob as you and basically what i figured out is that you cant realy rebuild a starter for a quad like you can for a car or thruck, you are better off to just buy a new one. There listed on ebay all the time.

 

i have spoken with atv mechanics and you can rebuild starters for atv's, but he says they will not last long, only like a cpl of months depending on how u use ur atv and what u go through. I just bought one off ebay for 97 bucks total, i just got the starter, the drive gear would have been extra, this was in a 95 the drive was very rusty but i wd 40ed the hell outa it and let it sit in a cup of oil, put in the old drive gear and it works fine, its not hard to replace the starter but it does take a while to getting in and getting at it.

 

What outfit did you do business with, I noticed there was a couple of them.

 

Ive bought from 14rebuilders on e-bay and have NO complaints! You can get the starter w/drive or w/o, also the starter drive alone! Their feedback on e-bay is WAY up there and alot ot it too. He ships fast and well packaged too. Ride Safe!!!!


Starter Drive $45.00

http://cgi.ebay.com/ebaymotors/NEW-S...temZ4598339519

 

yes i used them as well, all good here, i wold say with your model being rather new you wont need a new drive gear, mine is a 95 and a lil cleanign and oil and mine worked fine.. so u shouldnt have to worry.. but if you want to make sure take it apart before you order to make sure, also when i put my new starter on along with a new gasket i used some silicone to help seal it better, therefore less of a chance for water to get inside! also make sure when going through water to have your pull start firmly and tightly resessed back in so water doesnt seap down in from there..

 

In my post above you can get just the drive from Mfg Supply.
I also talked to auto elec. rebuild places and they will do it for about $80-100 including parts.

Jim

SMU5003 Polaris ATV Starter Drive 3085394 $155.00 $49.95 Purchase SMU9115


E-Mail:
If you have questions about a product, please e-mail us at sales@mfgsupply.com.

If you have questions about the website itself, please e-mail webmaster@mfgsupply.com.
Address:
You can write us at:

Manufacturer's Supply
P.O. Box 167
Dorchester, WI 54425
Phone:
1-800-826-8563
Fax:
1-800-294-4144