my '02 500h.o. has broke yet again..

The pull start this time, the cable is out all the way and not re-tracting, and the engine has stalled and struggles to start. Whats the fix it remedy for this? If I remove the section where the pull start is located will I be opening up any surprizes? Such as fluids or whatever, thanks.

 

should be anything back there cept for the bendix, flywheel and stator. as far as i know that is not an oil cooled stator.

more than likely your spring has broke for the recoil. i dont know if you can just buy the spring or if you have to get the whole pully thing that the rope winds up on and the spring.

 

Thanks for your reply. I looked on ebay and I have a better understanding of how this setup works now.

Is it possible I could remove the pull cable and just get rid of the pull start setup and plug the old hole? Or will it not run unless it has the pull start setup? Like I said it doesn't wanna start now. When it did run it sounded like a marble was bouncing around the case.

 

buy a new starter drive and remove all the pull rope stuff and plug the hole. do it all the time at the shop

 

I just tore down into it, I removed the panel the pull start is mounted to, and the cord re-wound itself back up. Now for the question, I found a bent small spring under the plate that fits over the pull start setup, how important is this? The pull start seems to pull in and re-tract properly off the machine. Can I just bolt it back together and call it a day? Remember I dont really intend to use the pull start again after this PITA experience.

The spring


This spring goes under this plate in the center, a little unsure of how though.

 

Nevermind the retracting part.... it just flung open on me, so i'm saying f**k it and putting the cover back on and hoping it will still start.

 

You don't have to have the pull starter in for it to start. Mine shattered and i just took it out for weight saving 1lb lol just hope your battery never dies or your up a creek.

 

Does it start? If not that spring rattling around may have messed up the stator.

 

It doesn't start/crank at all, all you can hear is the starter buzz. I'm real busy lately so i'll take this piece of s**t to the shop sometime when I can afford to.

 

Don't take it to the dealer, they charge too much learn how to fix it yourself.
the small spring operates the pawl that hooks on the flywheel when you pull the rope. So you need a new plastic rope reel. the reason the starter just spins, could be one of two reasons. either battery is not real strong and the starter doesn't spin fast enough to throw out the starter drive. Or the starter drive is seized the more likely problem. Don't buy one of those from polaris, there are much cheaper sources check ebay.

To get the starter drive out, I believe it should come out the back if you remove the starter. or leave the starter on and remove the flywheel. which will require a puller.