when the shaft is pushed all the way in don't hit the crank pulley what could be wrong?

look at pics

 

The bendix is bad, the part in your hand is spring loaded and should extend out and engage when the starter spins it

 

Yep I'd say thats your problem. Fortunetely they don't cost much though. Try Ebay NEW STARTER DRIVE BENDIX POLARIS ATV SPORTSMAN 500: eBay Motors (item 140469103691 end time Nov-21-10 11:46:14 PST) Make sure everything is sealed good when you reassemble and also silicon the pull start handle to help prevent water from getting in. Water in engine BAD!!!

 

got a new one try to start it all it does is click click what could be wrong?

I try to pull start it worked 4 times now even that wont work

 

Sounds as if something isn't lined up properly or sticking. The pull start has nothing to do with the electric starter. Also what kind of shape is your battery in?

 

checked my battery was at 9.6 I put on charger did nothing I got a new one have let in charge overnight hope this is the problem.

 

new battery work turn over just wont run? when I 1st put pull start on I got to start 1st pull let run now when I put all to gather all doe cranks.

What could be wrong?

 

If it would run before as you say and now it doesn't after putting it back together I'd go back in and make sure you didn't break any connection to the stator and also check your coil pulser/pick-up . You may have bumped it throwing off the clearance. I doubt it but you never know. With as much rust showing from the pic's it appears there could be water damage to some vital components in there.

 

clean the rust off the magneto and the flywheel, all that rust probably came from the pull rope handle not being sealed and water getting in there. take some emery paper and clean up the flywheel, there is a measurement between the pickup coil and the flywheel, not sure right now what it is, youll have to have some feeler gauges to measure, I'll look in the book and let you know.

 

clean the rust off the magneto and the flywheel magneto where is this at?