Has anyone ever put on a new starter? Just wondering what kind of knuckle job it is (I rank jobs by how many knuckles I bust doing them)? Any pitfalls I need to watch out for?

Chuck

 

I'd rate a four stroke starter job such as on the 325,330, 425, 500 as couple knuckle job, a two stroke starter job on the 250,300,350,400 a four knuckle job! Smaller the knuckles,the better Actually it's just more time is involved in the two strokes! OPT

 

Cool. I heard the polaris is practically built around the starter and you have to tear the thing down to get to it (that would be a 3 to 4 knuckle buster right there). BUT Haynes makes it sound like a quick and dirty pull it out and put er in (single knuckle if your sloppy) job. Figured there was more to it. I'm not afraid to tear her apart now that deer season is winding down but I want her back together before March for turkey season.

 

They're not too bad to change, easiest to get at it you take the belt cover and clutch off, then it's out in the open and a breeze.

 

I just did one on my 04 500 and it wast that bad you can get the one bolt out all the way and the other just back out and it hits on the rear clutch cover but you can rotate the starter with the bolt still in the starter ear until you clear the rear cover. You may need a screwdriver (long handle) to pry a little but it does come out. Just remember to install the new bolt in the starter ear before you re- install the starter (ask me why I know this) if I have to do one again I will have it done in 20 minutes not the 40 it took me.

 

Get your starters from DB Electric on Ebay. Half price!

 

A lot of times your old starter only needs brushes and it is no problem to change these and it is a lot cheaper than buying a new starter.

 

This was done on a 2007 sportsman 500 X2, but if the starter is on top of your motor it should be very similar.

After lots of searching i found people saying a couple different ways to get the starter out. The easiest way was to remove the starter below the airbox. So i did that today.

Polaris wanted $80 for the rebuild kit, or $400 for a new one. DB Electrical has rebuilt ones for $43 w/ free shipping. Polaris starter # 3084981

No fancy tools needed just a 10mm wrench, pliers, hammer, screwdriver and a torx bit. I cant remember which right now.. but it was either t20 or t25.

First off disconnect your ground. remove your seat and un bolt your airbox. You will see the starter on top of the motor.

Next you will need to loosen off all the hose clamps for both breathing tubes and any other tubes or wires in your way. It will be very self explanatory.

You will need the torx bit to move the brake fluid filler tube out of the way. 2 bolts.
Moved the brake fluid filler.


The starter is only held in with 2 10mm bolts. The one on the left will be too long to pull out while in the machine so you need to back it out as far as it will go.
10mm wrench


Screw too long to come out.


The starter itself will be pressure fitted in so i used a long screwdriver and a hammer. And hit the end of the screwdriver from the right side of the machine to push it out till it was loose.

Then turn the starter to the right, or towards the other hole. It will all come out together.

That is it.. probably took 30 mins. not even.









done.. awaiting new starter.