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changing a starter on 2005 sportsman 500

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Old May 18, 2009 | 03:31 PM
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Default changing a starter on 2005 sportsman 500

does anyone have any advice on changing starter? will i need too remove clutch? ive removed both bolts on starter and still cannot remove its jamming on clutch cover unless im missing something. any advice wiil be appreciated thank you.
 
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Old May 18, 2009 | 08:59 PM
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I recently had the same problem on my scrambler 500. I ended up removing the air box and was able to just barely get the starter out through the top. I'm not looking forward to reinstalling the new one.
 
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Old May 18, 2009 | 10:16 PM
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thanks elusive i might have too try that before i remove clutch
 
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Old May 19, 2009 | 08:51 AM
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Starter Drive Removal/Inspection from my book

Remove recoil housing bolts and remove housing
Remove starter drive assembly . Note the thrust washer located at the rear .
 
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Old May 19, 2009 | 09:40 AM
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The only thing behind the recoil housing it the bendix drive not the starter.

My Manual told me to get special tools and remove primary and secondary clutches to remove back belt housing plate just to make room to remove one remaining bottom starter mounting bolt!

Instead this is what I did. I took out the air box and removed the top easy starter mounting bolt. With the bottom stubborn mounting bolt you just back in off until it hits the backplate of belt housing,it will not come out but will disconnect.
Than I used large channel locks and turned the start clockwise until the bolt was at the 12 O'Clock position and slipped the bolt and the starter right out no problem.

I can,t believe my " Clymer" manual wanted me to tear down half the bike to remove one bolt!

BTW it turned out one of my starter bushes was sticking so I cleaned it up and it works great now.
 
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Old May 19, 2009 | 02:17 PM
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Originally Posted by TLC
The only thing behind the recoil housing it the bendix drive not the starter.

My Manual told me to get special tools and remove primary and secondary clutches to remove back belt housing plate just to make room to remove one remaining bottom starter mounting bolt!

Instead this is what I did. I took out the air box and removed the top easy starter mounting bolt. With the bottom stubborn mounting bolt you just back in off until it hits the backplate of belt housing,it will not come out but will disconnect.
Than I used large channel locks and turned the start clockwise until the bolt was at the 12 O'Clock position and slipped the bolt and the starter right out no problem.

I can,t believe my " Clymer" manual wanted me to tear down half the bike to remove one bolt!

BTW it turned out one of my starter bushes was sticking so I cleaned it up and it works great now.
Your right I just looked through my $80 buck POPO manual and all it says about the starter motor is " Remove the starter from the engine " says nothing about the procedure to remove it unbelievable .
 
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Old May 19, 2009 | 07:14 PM
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thanx for the help
 
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