I bought a 04 Sportsman 400 last fall used, and the starter has been getting weaker and now has failed completely, looked on the bottom of the motor like my old sportsman 400 2 stroke and realized this starters on top, anyone changed one of these yet, and how hard is it. Does it take the same sarter as the other 400s or no, any info would be great. Thanks

 

The 4 stroke 400 models use the same starter as the 425 and 500 engines - you can pick up a new one off Ebay for around $120 w/shipping. -these are not the same as the 2 stroke models.

To remove the starter you really need to take the Primary clutch off (3/4 fine thread, tighten as much as possible, then hit puller "head" with a hammer to break loose - repeat if necessary) to be able to pull back the inside clutch cover for easier starter removal - other than that it is just simply unbolt the 2 starter bolts and the starter cable - when putting the new starter on, apply a little grease to the O ring, it will slide in easier.

 

Thanks Quadwrench!

 

be careful here though. i have a friend who has a 400, he experienced the same thing starter seemed to be gettign weak. he took it in to the dealer as it was new. he said it had shattered some gears in the drive. they fixed it. he loaded it up and before he could cut it off he heard a pop. he walked back into the dealer and told them, they came out pulled something off and it had happened again. they fixed it a second time, then he went to pick it up again, he rode it around more this time. he loaded it up fine and drove home. to check to see if it was ok he decided to ride the snot out of it at home. it did ok until he went to park it, it wouldn't shut off then. he had to pull the battery cable off to get it to die. just wanted to bring this up so when you are doing this work, make sure you check all the components out thoroughly!

 

Just to let you know, the starter can be change out without removing the primary clutch assy. I did mine by only removing the outer clutch cover. It's about a two beer job, three if it's over 85 degrees. [img]i/expressions/face-icon-small-smile.gif[/img]

 

How did you get the starter out with the inner cover in the way? I thought Id go the same route, I got the starter unbolted but there is no room to pull it out of the case.