I have a 99 Sportsman 500 which I have owned since 02. It gets lightly used maybe once a month at best. Recently when I try to start it, the starter engages and turns the motor over for just a few revolutions but then disengages very quickly. I end up having to keep engaging the ignition switch until it finally starts. Once it starts, it runs fine and seems to restart fine until the engine cools down. Within the last two years, I have replaced the starter (along with new cables), the bendix and the battery. I my frustration trying to get it started one day, I tried pull starting it only to ultimately break something in the recoil housing - the rope pulls out and recoils, but does not catch. As such, I know I need to get into the recoil housing anyway. Any advice would be greatly appreciated as I am trying to get ready for deer season which is just a couple of weeks away.

 

You probably broke the ratchet lever that engages the flywheel. Pull the recoil assembly off (8mm bolts) around the cover and remove and inspect. A lot of times the plastic reel breaks also where the ratchet and small return spring mount. You can look up your parts breakdown on your model at Cycle Parts Warehouse. OPT

 

Thanks for your advice on the recoil starter issue - while I haven't pulled the starter case yet, I figured that which you suggest is probably the problem. Any advice on my primary starter issue (inconsistent electric starter engagement??).

 

my old 700 would do that, I found it was a weak battery, try puttin a battery tender on it for a while and see if it starts better

 

Starter bendix early kickback can be because of worn teeth on the flywheel or bendix, not allowing full engagement, or a weak battery(may hold 12 volts,but amperage may be low) causing bendix kick back. Plus might be a good idea to pull the cam cover and check condition of the cam. This model along with earlier 500s had a problem with excessive cam wear on the exhaust lobe,plus cam decompression spring or release lever spring(as its called) may be weak or broken not allowing lower compression which would put extra pressure on the bendix, starter, and battery while trying to start. Plus one other thing a lot of people over look are the two bushings in the cover and engine case where the bendix rides. I've found them galled,cracked,which would put the bendix in a bind also. OPT

 

my first suggestion is to check the valve clearance. if the valves are on the slightly loose side, they might tap a little. once your engine starts and starts to get warm, metal expands, and the clearance gets slightly smaller