Hello everyone,

I have been searching on the forums and have found a bunch of information regarding my issue, but nothing quite speaks to me or mentions my exact problem in detail.

I have a 2003 Polaris Sportsman 500HO and am unable to get it started. At the end of last season everything was working just fine, but i guess storing it over the winter broke something.

When i turn the key all i get is a spinning sound, at no point does the engine 'crank' or even try to start, only a winding/free spinning sound. I have put a multi meter on the battery (which is brand new, and was charged) and am able to get a 12v reading from it. Also i have put a multi meter on the starters negative wire, and the starter positive wire at a junction box in between the battery and starter positive terminal, and can also pull a 12v reading. From the research i have done that should rule out the battery as well as the starter being bad, correct? (along with the fact that 'something' is getting power)

Next moving down the list I saw that a lot of people had a problem with gunk or rust inside the right engine cover which holds the pull cord recoil, and coves the flywheel and starter bendix. So i took this cover off and it was actually quite clean in there, but i got any excess grime out. While doing this i also pulled out the bendix and inspected it. At first i thought it was working perfectly, as i could move all the parts around freely, but after playing with it for a bit i noticed the top 'plunger' type piece was not pushing down all the time, and would sometimes get stuck so i was hopeful that i had just found my problem. I ordered a new bendix online and put it in the other day. Hooked that battery back up and turned the key. Same exact sound........ Nothing had changed.

So once again i took the right engine cover off, and while it was off i attempted to start it. I can see the starter spinning, which is in turn spinning the new bendix, but the bendix is never actually extending out (not even a tiny bit) so that the teeth can engage the flywheel and start the engine. So now i am at a loss as to what i should do/check/replace next. Any expert advice from everyone would be greatly appreciated.

 

Make sure you have the thin washer behind the bendix. You can push the cap of the bendix down and grease the shaft along with a small amount of penetrating oil on the rest of the bendix. Rotate it several times and wipe off any excess oil. Also make sure the cups in the recoil and in the case the bendix rides in don't have any burrs or rough spots that would slow/stop engagement. Sometimes you'll get one like this that may have been sitting a while on the shelf.

 

Thanks for the info! I did read somewhere about that washer/spacer on the back of the bendix. The new one did not come with one, and on the old one honestly i dont know how to get it off, haha. I dont believe there are any burrs around those areas, but i can double check that this evening when i get home. Also I can lube things up a bit better to see if it makes a difference.

 

OK, so i went in and pulled the bendix out again and inspected the inner area where it sits,and found no burrs or anomalies, everything is nice and smooth, and nothing stands out. I also lubed up the bendex. I was still unable to remove the washer/spacer from the old bendix, got any tricks for that, or can i just purchase a washer that is the same size?

None the less i put the bendix back into the casing, but am still running into the same issue, the bendix is spinning very freely, but is not engaging the flywheel. Any other parts that would prevent the bendix to not extend when in motion?

Thanks!

 

A little trick is to remove and stretch the spring once in a while. I bought a after market Bendix for $70 Canadian that has lasted 5 years now if all else fail.

The dealer wanted $170.

Here is one for $21. NEW Starter Drive Bendix Polaris ATV Sportsman 500 | eBay

Here is a good video on it.
Polaris 500 Sportsman Starter Bendix Replacement.m4v - YouTube

 

Use a razor knife or razor blade to pry it up. If the washer is deformed or worn down just try to match one up at a hardware store. It needs to be the same thickness,no thicker.Hopefully the new bendix will work when you install it. If it still does the same thing,check the teeth on the flywheel for any damage.

 

Hey TLC, this is a brand new bendix, I would hope that I would have to do anything different with it in order to make it work. Also i did watch that youtube video, that actually is what helped me get to where the bendix was.

Old Polaris Tech, I will have to try a bit harder to remove that spacer this evening, and if all else fails get a new one. I have inspected the teeth of the flywheel and everything looks perfectly fine, no sign or wear or broken teeth.

 

I was able to get the spacer removed from the old bendix and moved over to the new one. But I am still having the same issue with the bendex just spinning and never extending to engage the flywheel. Could this be a bad bendix? I kind of think not, as this is the same behavior I was having with the old bendix. Does anyone else have any ideas?

 

If you were having the same issue before on the old bendix not engaging,then either sounds like the battery may not have enough amperage to spin the starter motor, the starter brushes could be worn or dirty causing it not to spin fast enough to kick out the bendix,or it's the engine or recoil bushings binding.Somethings stopping it from engaging..

 

did you ever figure this problem out I’m currently dealing with the same thing