Hey guys, I've bought a used 2003 sportsman 700 twin and been riding it for a few years now with no troubles. While ice fishing this winter however I seemed to have come across a major problem. The quad was running fine no problems untill one morning i went to start it and now all i can get is a loud grinding noise when i turn the key! Sounds like maybe the starter is slipping? I've noticed the sound has happened a few times before such as when trying to start the quad with a low battery, after turning over a few times it resorts to the grinding sound until the key is let go. This leads me to think that perhaps the problem could be electrical?? No matter how much i charge the battery the problem still persists, the grinding just becomes louder/faster the more charge the battery has lol.
I really don't want to have to bring it into the city to the dealer to have it looked at so if anyone can offer me some ideas it would be greatly appreciated! Thanks ahead of time!

JR

 

welcome welcome jr. it sounds like the start isnt engauging right or disengauing or maybe the fly wheel teeth are messed up. i would pull the starter off and take a peak.

 

Had the same thing happen to my 03 700 and it turned out to be missing teeth on the starter gear and bendix.

 

Yikes... haha! Yeah I was worried most people were going to say that. It happened on my truck, and not only was the started stripped but the ring gear on the flywheel had some damaged teeth. a.k.a. Big $$.
Well, Can I pull the starter fairly easily? Like without having to take whole side casing off? I'm heading back up there next weekend so im hoping to be armed with all the knowledge necessary to tackle this project haha!
JR

 

Welcome, you can go to look at some parts diagrams to see what parts your looking at. Polaris has a site or you can go to www.yourwaytofun.com and clik on online parts diagrams. Their a Polaris dealer in Minnesota.

 

Great site! Thanks for the info! Looks like this isn't going to be a cheap fix by any means. Hopefully it's just the bendix thats bunged up, and not the flywheel.
Can anyone explain this whole stator buisness? Is it right in there with the flywheel? Im used to rebuilding small block chevies, so this whole electronics thing on starter side is new to me. Is it simply the charging supply for the system?
Thanks again!
JR

 

Yea you got it. Don't worry about digging in their. I just pulled my side cover off, pulled my flywheel, and replaced my water pump seals. Not to bad of job but be sure if your going to pull all that stuf off that you have th correct gaskets on hand. Also I had to use heat to get my flywheel off with my puller. I was careful not to get it to hot as to melt the stickum for the magnets on the flywheel. I can not remember if you have to pull the flywheel to replace the bendix, but I don;t think you would.

Good luck, trailbound

P.S. I just replaced the starter bendix on my dad's 20 hp kohler magnum lawnwower.

 

Sounds awesome! Yeah I think from looking at it i should be able to pull the starter and bendix right out without pulling the wheel. I don't think ill even have to take the side cover off. Thats how the story goes on vehicles anyways?
Were your water pump seals part of the problem as well or no?

 

Trailbound, I should also ask: No matter how much coolant I add into the rad/recovery bottle, after a few rides I notice it slowly deminish in the recovery bottle. I've read some posts on this and they all point towards water pump seals. Does this sound familiar? Another major job, or not so bad?

JR