I've got most of my 06 sportsman project sorted but I gave it a test ride yesterday and noticed this rattling noise coming from the pull start housing. At idle it does not make the noise but anything above that, I can hear it. I replaced the starter motor as the previous owners just used the pull start (Maybe wore something out?). Could it be the Bendix? or something in the pull start assembly? Also, was getting the battery symbol flashing intermittently. Checked charging and it is charging above idle at a little over 14V. Does it under acceleration sometimes. I checked ECM and it is the silver finned made in USA model so I assume the recall was don on this machine. Machine runs great, all systems seem to be working.

 

Bendix itself rattling,vibration from worn bendix bushing in the recoil cover or engine case.Could even be noise from recoil friction plate if the bolt has backed off a little. Any way I'd pull the recoil cover off and check things out.Seal the recoil with a good rtv sealant such as Threebond,Yamabond,etc. Plus a lot of people silicone the rope handles.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
As far as the "silver" Shure Power ecm, just because it's been replaced doesn't mean it hasn't started to fail just like the Chinese ecms did. I replaced multiple ecms on the same machines..
Check that your battery cables are tight and that it's charging 14-14.5 volts at an idle. If it is charging ok,have the battery load tested for a dead cell.

 

Thanks Old Polaris Tech. Are the Bendix bushings replaceable? I do suspect the battery as the previous owner allowed it to go flat a number of times and the terminal screws are also pretty beat up. I put the charger on it yesterday and it took about 3 hours to show a full charge.

 

Yes,but some are tough "if" they need replacement.You should be able to tell real quick.Usually it takes years for them to wear out,but anythings possible. I always just dremmeled em on one side or just cracked em with a small sharp punch. Then they come right out. Even a little heat on the bushing from a heat gun will help.

 

Not many hours on this machine so I'm hoping its not that. I'm also hoping that at least the USA made ECM does not go up in flames as the Chinese made unit did.

 

No hopefully not in flames,but can just melt like this good American made module did..

 

Thanks for the picture OPT. You know the weird part about the battery flashing on my ATV is that it does not do it in neutral no matter the RPM. But it does it almost exclusively under acceleration. It blinks, then stops when I come to a standstill. Charging rates seems a-ok. No overcharge, no undercharge. Maybe the battery connections or a loose connection or ground. I do have a battery tender lead hooked up to it as well. Never really liked the fact that the ring terminals have much bigger hole than necessary for the terminal bolts. Never really felt you could get the leads tight. They are a major convenience though. Might remove it and try it again. Battery looks like its been through a war (Sealed unit)...which is pretty weird in itself. Don't know how old it is so I may just get a new one just to eliminate that possibility.

 

The Bendix are rattly . Sounds like a can of marbles every time I hit the start button.

Usually the rattle goes away once the rpm is brought up above idle.

 

TLC...mine is just the opposite. No noise on startup and at idle but sounds like a can of marbles above idle on up.

 

Tighten the battery connections and just check charging at the battery. At least this will tell you whether it's an ecm problem as it controls charging along with fan operation,etc.If you suspect the battery have it load tested at any auto store.Load testers are getting cheap enough now to keep one in the tool box to use on every vehicle you own. 100 Amp 6/12V Battery Load Tester