Just a follow-up, I bought new batteries. The 800 runs great and is much more comfortable with the pre-load shocks maxed out!!

The 400, though... Lights work, dash, everything. It will run with recoil starter. However, the starter spins. It won't engage with the flywheel. So....add another project to the already loaded-up to-do list!!!

I read a few posts about removing the starter. Some say you can do so after removing the airbox. Others have gone through the work of removing the clutches and covers. I am sure that makes access to the starter easier...but it take a huge effort to get there!!!

Hopefully this is something that can be fixed with a good cleaning!

 

If the starter is spinning,but the flywheel isn't engaging,it could simply be the starter gear shaft(bendix) behind the recoil. Easy to get to and grease if needed or replaced,just wiggle it out. Here's a cheap one. DB Electrical - NEW Polaris ATV Starter Drive Bendix 2&4 Stroke Engine 6191-2962

 

I, too, felt it was the bendix just sticking. Are you saying if I remove the recoil cover I can pull the bendix out that way w/o the need to remove the starter? If that's the case, that would save me a crapload of time!!!

Would that be the same for the 99 trailblazer? Because we have never used the recoil starter on that one and when I tried yesterday I found it doesn't work. I would imagine it is frozen up from lack of use. So, I could inspect that and clean it up while I'm in there!!

Does the bendix go bad? I just pictured it being corroded or dirty and I would need to pull it out, clean it and make sure the spring was good - assuming it's like a car starter and the bendix torques out on a spring...

 

You can pull the bendix out on the 500,but on the 700,800 you have to remove the flywheel.Same thing on the 250 and 300 2 strokes,the flywheel has to be removed,OR it can come out backwards with the starter if you have to pull it also. Cheap as you can get them I wouldn't try to repair an old bendix or starter for that matter and then you may have to go back in later if it/they fail again. DB Electrical - Polaris

 

OPT, thank you very much! I did pop off the pull starter, cleaned it all up - yes, very gunky in there!!

Pulled out the recoil starter coil itself, spring, etc and cleaned all up. Popped the bendix out and it was frozen. With the timeframe I am working with there is no time to get a new one so I wire brushed and PB blasted the hell out of it and got everything loosened up.

I may purchase a bendix and throw it in the parts box b/c it looks like we have several machines that use the same one.

Now...pulled the flywheel cover off the 250 and - bam - can't get that bendix out - just as you stated. Looks like a I may need a harmonic balancer puller or similar to remove the flywheel. Have any advice for removing that? I can see I need a new pull rope as well!!

Thanks!

 

If the bendix is all you need and the starter is good on the 250 then yes a "loaner" harmonic balancer puller from Autozone, O'Reilly's,etc is the best to pull the flywheel or just buy a cheap steering wheel puller. You need ( 3) 3 inch 8mm bolts for the flywheel as some don't come in the kits. If the starter is suspected of being bad also you don't have to pull the flywheel,but best to pull the clutches,backing plate,etc to get to the starter mounting bracket.Then you can pull the starter and bendix out as a unit.