2001 Sportsman 500 HO. I just replaced the stator, bendix and recoil assembly. It didn't start at all before. Now it does eventually. Most of the time it makes a grinding, spinning sound like nothing is engaging. If I let up on the start button a couple of times it fires up. Sometimes it fires up instantly (like it should). Any ideas?

 

Grease the bendix when you installed it? If not it can be dry and hang up or not kick out to engage the flywheel.Plain old grease is fine at each end and along the shaft when you push the bendix collar down. Plus a lot of people over look the brass bushings in the recoil and engine case the bendix spins in. If either one is galled or chipped the bendix can hang up or not operate smoothly. Plus as a rule of thumb on the 500 I always"blipped" the throttle right after cranking as the 500s have a habit of hanging up against the flywheel teeth to begin with. This kicked the bendix back away quicker. Higher torque machines like the700/ 800 models and up didn't have that problem as they really had the torque.Also did the new bendix come with a washer? If not like a lot of them, you have to use the old washer off the old bendix. Not having it on can cause problems also.

 

Greased everything you mentioned. I'll take the cover off and inspect where the Bendix spins in as the cover is new. It did come with a washer. I may re-install the old Bendix too...

 

The bad news is the brand new Bendix is bad. The good news is the old Bendix works. The machine is starting great now! Thanks for the help.

 

Can happen as they're made in Brazil,Mexico,China and elsewhere. Seems like on mechanical parts like this there should be some sort of testing on the assembly line to see if they function properly,but that would probably raise the prices..

 

Exactly. I called the company I bought it from. They said not to send it back and they would credit me the $17.00 I paid for it. Must have cost them about $5.00