I have an 03 500 HO. I've replaced two starters and a starter drive gear due to water getting in my pull start casing. The unit originally came without a gasket on that side and I had to order one from a previous year in hopes of eliminating this problem. I can only assume that the water is getting in thru the starter shaft where it enters the casing and I put alot of grease around this area to minimize water entry. I was in west virginia last weekend and having to leave the quad outside overnight found it completely frozen the next morning, starter gear AND pull starter..immovable. It eventually defrosted on the ride home to Northern Virginia. Anyone had this problem and anyone know of a solution? Don't suggest avoiding deep water cause that aint happenin...Thanks.

 

Water is probably coming in at your pull start rope.

 

The problem you describe is the one big reason I’m not sorry to see the recoil start system eliminated from most of the twin motors. Even if you do all you can (sounds like you have) that housing is going to take on water if you ride the deep stuff. All I can suggest is stay on top of your efforts to seal it and drain it after you ride. If your problem is that severe, you’re almost better off leaving the drain plug out (almost).

 

ive never had water in mine, my rope is dry and white all the way to the end. mine has been submerged many times too. i would say to take some clear silicone and seal the handle to the case. if you have to use the pull rope it should come loose without to much resistance

 

My 02 model has a self tension clamp on he pull handle to help seal the housing off. See if you have lost yours. May have to silcone it good.