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04 500 sportsman starter

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Old 08-02-2010, 10:27 AM
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Default 04 500 sportsman starter

I am trying to change the starter and can't get to the bottom bolt. Any suggestions????
 
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Old 08-02-2010, 10:50 AM
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My Manual told me to get special tools and remove primary and secondary clutches to remove back belt housing plate just to make room to remove one remaining bottom starter mounting bolt!

Instead this is what I did. I took out the air box and removed the top easy starter mounting bolt. With the bottom stubborn mounting bolt you just back in off until it hits the backplate of belt housing,it will not come out but will disconnect.
Than I used large channel locks and turned the start clockwise until the bolt was at the 12 O'Clock position and slipped the bolt and the starter right out no problem.

I can,t believe my " Clymer" manual wanted me to tear down half the bike to remove one bolt!

BTW it turned out one of my starter bushes was sticking so I cleaned it up and it works great now. I also put that blue gasket goo everywhere a o ring was, to see if that may help water proof these Polaris starters once and for all.
 
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Old 08-02-2010, 10:55 AM
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thanks. I will go home and try that tonight. You would think they would make that alot easier to do but I guess they want you to take them in and let the "professionals" do it.
 
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Old 08-02-2010, 03:23 PM
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Originally Posted by atk795
thanks. I will go home and try that tonight. You would think they would make that alot easier to do but I guess they want you to take them in and let the "professionals" do it.
I took out aribox...took me 10 min to exchange...good luck
 
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