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.

 

Thats how I did it also, all the manuals say to take the clutches off and belt housing backplate! Now that would suck. LOL

 

yeah, hopefully this will save someone alot of headache.

 

Well i got my new / rebuilt starter in the mail today.. Very fast, less then a week.
Got it back in no problems. Started great..
Edit: the torx bit is the t-25 for the brake fluid filler.
Pics..






My shop... glad it decided to snow today. :P

 

I can't describe how much this post helped me! I was not looking forward to removing the clutch. I is a very tight squeeze but with a rubber hammer I got the new starter in. Worked great!
Thank you!

 

awesome.. glad it helped.

 

Thanks for this, gotta change mine tomorrow was ready to pull clutches thanks again

 

Well a couple months later... less then 10 rides.. and back to square one. Broken starter. I took it apart and found the wire going from the brush out was broken.. good times. And the main section looks a little weird to me??
I hope db electrical will warranty the parts or something.

 

Are you sure your bendix has been kicking out as soon as it starts? That Armature sure looks like it has been over revved as it would be if it was kept engaged. Please keep us informed what you find out.

Fred

 

interesting. Maybe that is the problem. I took apart both my old and my new starter, They both had thee same problem. the main wire coming in broke from the brush.
Would the bendix cause that to break / fry as well?