I have a 1997 sportsman 500 that the pull starter rope snapped awhile back. I always assumed that the noise coming from the flywheel area was due to this until I started reading about the bendix problems on these machines. So I am now assuming the bendix is making the noise from this area. Well I have removed the flywheel cover and am trying to remove the bendix without removing the flywheel itself. I have read people say you can remove it without removing the flywheel but how? For the life of me I can't get it out. Any advice?

 

You have to pull it out of the bushing in the engine case,angle the bendix to the left and wiggle it out of the case. Starters and the bendix are cheap. If it's the original just replace it.Make sure you have the washer on the rear of the bendix. If the new one doesn't have one,just reuse the old washer. You can get cheap starters and bendix here. DB Electrical - Sportsman Or ebay has them. http://www.ebay.com/itm/NEW-STARTER-DRIVE-BENDIX-POLARIS-ATV-SPORTSMAN-500-/111294712281?pt=Motors_ATV_Parts_Accessories&hash=item19e9ae89d9&vxp=mtr
While you have the recoil out,check it out along with the bushings where the bendix rides. Have had a few worn/cracked over the years. Item #9 in the recoil cover and one in the engine case. http://www.cyclepartswarehouse.com/f...1997&fveh=5443

 

Usually the Bendix falls on the ground when I take the recoil cover off. Just grab it and give it a wiggle.

Fast forward to 6:00min into this video,but it has other handy info.

 

Good video! Use any color sealant on the cover except RED! Stands out like a sore thumb and looks like an amateur job. Thin coat of black or preferably silver rtv. Cute kid too..

 

Sealing the rope handle in place was another good tip he gave.

 

I received my new bendix in the mail today. After examining how it functions and looking at mine which is still on there I see the problem. Mine is stuck out. I have lubed it tapped it a little and tried to twist counter clockwise to make it go in and still no luck. I guess I am going to have to remove the flywheel. Any tips or advice?

 

Take a hammer and tap the bendix cap down. Use penetrating oil such as PB blaster to try to loosen it up to where it can retract so you can remove it. Work with it a little,better than having to pull the flywheel.

 

The bendix will not go back in for anything. Is there anything specific for pulling the flywheel? It looks to me like it is pretty basic r&r. Obviously I need a puller but any other advice? Do you happen to know the torque spec for the flywheel nut replacement?

 

If bendix is that rusted that you need a puller,just go to most auto stores and"borrow" a harmonic balancer puller if you don't want to buy one. The three screws in the flywheel are metric. May or may not be in the kit,but any hardware store has them. Performance Tool W151P - Harmonic Balancer Puller | O'Reilly Auto Parts Fly wheel nut torque is 58-72 foot pounds,but most techs that have done this a while just zap em with an impact. Shaft is tapered.

 

Got the flywheel removed. The bushing that the bendix slides into has several stress cracks. No pieces are missing though. I'm assuming with even stress cracks I should replace it. How does it come out?