I need to replace the starter on my 03 Sportsman 500 HO. The book tells me to remove the clutch cover and actually I think the entire clutch unit! I removed the cover thinking that maybe that would do the trick but as it turns out there is one bolt on the starter (the lower one) that CANNOT be removed unitl the entire left side of the quad is removed!! Is this a fact or is there another way? AS well, if I do have to remove the clutch unit does it come off as one piece or do I need specail tools, extensive knowledge, etc? The repair shop is gonna rape me, I would certainly prefer to do it myself. Any advice on this project? Thanks.

 

The secondary clutch does not need a puller, but the primary clutch does. You can get the starter out without removing the back cover. On my scrambler, I had to remove the secondary clutch, the bolts that hold the back cover on, as well as the entire airboc and carb to get at the starter. And with the right combo of wrenched and sockets I was able to finagle that last bolt out. It would have been MUCH easier if I would have bought the clutch puller and done it that way though

 

taken many off without removing clutches or covers. the lower bolt will come out, its just tight to get to and you can pull the cover far enough to allow the starter to come free. or as bbs said, buy the puller and do it the right way. puller doesn't cost that much

 

I just replaced the one on our 96 sp500, if it is the same as yours, one of the starter bolts should come out and the one on the bottom will unscrew all the way but wont pull out. You have to pull the starter back out of all the gears then up. The last bolt will come out with the starter.

 

Thanks for the tip. When i read your response I immediatley went to my garage and started playing with that starter. You were right, the bottom bolt finally came out and as i worked the starter back and forth it pulled out without having to remove the clutch assembly. Whew! what a relief that was. The bottom bolt was a bear to get back in but it happened, the tips of bothmy index fingers were sore for a day and a half.