I did a search and have read quite a bit about this subject, but I would still like your opinions om my problem. The starter on my 96 500 Sportsman seems to turn just fine as I installed a new battery, which needed to happen regardless of the starter problem. The motor will not start however until I pull the recoil starter. When the starter is turning there is a popping or grinding sound which has definitly gotten worse and louder over the past few trips, but even during the time these noises were heard the quad had started before. Now it's a no go with the electric starter, but a first pull start with the recoil. What would be the best way to find out what I need to do without a dealer trip? Thanks for your input.

 

seems like your starter held its breath for as long as it could. make sure all the leads going to the starter (positive cable) is not rusted out, loose, dirty or making a bad contact because the nut is loose. also check the positive lead from the battery. make sure thats nice and clean too and nice and tight. then follow that red positive lead from the battery to the selenoid and make sure the leads there are nice and clean and tight. the sufaces to all the leads where they make contact to the surface of the baterry, selenoid, starter must be absolutely cleaned from rust and debris with a wire brush.

 

 

oh yeah and dont forget the black ground wire. follow that too and make sure that is cleaned out with a wire brush where it connects to the battery and to the motor or frame of the atv.......................

 

Is the bendix gear stripped off?

 

Thanks for the replies. I am not sure if the bendix gear is bad or not, what is the best way to tell? That may be the problem as it feels like the starter is turning fine except for the noise. Thanks again

 

Don't know about a 500 but on my 95 400 you would remove recoil housingand pull the flywheel and there it is.Stripped mine before.
Steve