Just did this job on my 2005 500 HO. There was no need to cut the bolt. I was able to use a pry bar against the back of the clutch housing, just like he does and was able to remove and install without much issue. Thanks for the information sir!
On that lower bolt - remove the outer clutch cover and press the inside cover to pull it away from the lower bolt. Just enough room to pull the starter with the lower bolt removed using long needle nosed pliers. 23 years on the factory starter and I'll rehab and lube it it and keep it as a spare. Cutting the lower bolt is not a wise idea.
Dude, thank you for this tutorial, couldn’t have done it without it 👌🏻. Luckily didn’t had the bolt issue, got it out and in relatively easily. Thank you so much
Very nice video, I was trying to figure out how to get around that clutch casing without having to pull it out. You made it look easy. Good clear directions. Thank you.
Great video. Enabled me to put my starter in my 2003 Polaris Sportsman 6x6 myself and save a couple $100 at the shop. I found it helpful also to remove the air cleaner under the seat and above the starter. Gave me better access to the bottom bolt and to grip the starter to remove and replace it. Thanks for posting!
Attention everyone who is watching this!! Do not pay attention to this video!!! YOU DO NOT have to remove the clutch cover or drill holes in anything... Disconnect battery first, remove the air cleaner housing to access the two 10mm bolts to the starter, remove clutch vent tube, disconnect positive wire on starter, loosen two bolts from engine case completely, its very important to leave the rear bolt in starter hole and twist starter clockwise to remove when standing on right side of machine, it's very simple. Install in reverse. Takes less then 15 minutes.
Thanks for the video. Better than the video that removed everything including the decals to change the starter. No need to shorten bolt just put in and rotate. Total job took 10 minutes.
Thank you for this video !! My dad was trying to replace the one on his 2001 Sportsman 330. He came to me and asked to find a video on how to get clutch off etc. while he was working to get it off anyways. I came across you video first thing and stopped him from "tearing into it". We watched the video together and now we're going to get it fixed. Great Video !! Thank you again !!
Works on a 2004 sportsman too Cutting down bolt was a difference maker. If you use a ratchet wrench, place it on that right hand bolt before you rotate into place and can use a long screwdriver to give a little pressure and seat that nut easily
Just replaced the starter on my 2008 sportsman 500 EFI, this video was very helpful and made changing it a whole lot easier. Only deference is that the bolts are a 8mm instead of a 10mm on my model.
Swapped the starter on my 01 Sportsman 500 today and this saved me a ton of headache, thank you! I also ended up popping the intake duct to the right of the starter out of the headlight pod which gave me a little more room to rotate the starter and remove it.
This video helped me tremendously first time I replaced a starter on a wheeler only thing I didn't do was cut the bottom bolt which means I'll have to rip it all back apart since I cant get it in there now but great video!
Thanks for a very helpful video. On my 04, the clutch vent goes over the tank, so that's a bit of an issue. But, I managed to get the starter out. Time to put the new one back in. Wish me luck!
Thanks for the great video! It's very clear and helped me a great deal in pulling out my starter on my 2006 Polaris Sportsman 500 EFI. Unfortunately, I found I had to pull off the front cab to remove the clutch exhaust vent pipe that wraps up over the gas tank. After I cleaned up the starter armature a bit, the starter worked normally. It seemed to be coated in dust from the brushes.
thank you for the vid, it helped me out a lot with a 2005 polaris scrambler 500. i love the quad, i hate paying for small repairs when i can youtube and learn a little while i'm at it. thanks again, trevor
2001 Trail Boss 325 2001. After "n" years of not being used, when I installed a new battery and tried to use it, it broke out and no more sign of life. With the tips from your video I was able to uninstall it and found rust everywhere. I am waiting for an aftermarket to install. Your tip for cutting the screw is great. I'll tell you how it went. Thanks from Portugal
Removed the air box and clutch vent tube on my Scrambler 500, want able to get the starter out without it. Made the bottom bolt a bunch easier as well. Appreciate the tips.
Thanks! That was great advice. I did this on my 2005 500 Sportsman without undoing the front of the clutch vent tube, just pulled the back to the side. Tricky job but if you're mechanically inclined and somewhat of a contortionist, it's a lot less work than pulling the clutch assy.
Helpful idea to spin the starter to get the bolt on top in order to pull it out. Hoping that works on my ‘04 400 so that i don’t have to fool with the clutch assembly. Like the idea of shortening the hard to get to bolt a bit once its out before replacing new starter...
im doing this later today .can a person take outside clutch cover off drill a 1/2 inch hole inline with the pain in the butt bolt and pop a plastic fender plug in the hole , case isnt water tight any ways ??
Maybe this will help someone. I have a 2010 polaris sportsman 500 HO and the starter went bad (would start if I tapped starter with hammer while turning key) My starter mounting bolts have 8mm heads. Do not use a 12 point 8mm box wrench or you will strip the head especially on that lower mounting bolt. Instead get a 8mm 6 point box wrench or a 5/16" 6 point box wrench will also work just as well. After the head began to round using the 8mm 12 point wrench I switched to a 5/16 6 point wrench and using a big flat blade screwdriver to keep the wrench securely in place on the bolt head I hit the wrench rather hard with a big hammer and the bolt broke loose
Polaris sportsman 400 won't start after I cleaned using water to hosing it. It turns over but won't start at all. I need your help. I like your video👍Thhank you.
Could you tell me or put up a video on how to change a starter on a 850 Polaris sportsman I think it's the starter came out to start it one day and turned the key and it just went click click click I tried seeing if it was the starter by plugging in jumper cable from a good battery directly to starter and went to turn the key and nothing
Attention everyone who is watching this!! Do not pay attention to this video!!! YOU DO NOT have to remove the clutch cover or drill holes in anything... Disconnect battery first, remove the air cleaner housing to access the two 10mm bolts to the starter, remove clutch vent tube, disconnect positive wire on starter, loosen two bolts from engine case completely, its very important to leave the rear bolt in starter hole and twist starter clockwise to remove when standing on right side of machine, it's very simple. Install in reverse. Takes less then 15 minutes.
hey sir i know that this is an old video but i followed this and double checked everything and it’s making a weird noise like almost a squeaking noise then it starts
Hey Mark I just got a 2004 500 ho and it wasn't all there lol my question to you is I had to buy a starter solenoid and cables I and there is where my question lies. The solenoid came with the cables I know one goes to battery one goes to the starter off the solenoid but there is another that is spliced to the always hot side I have no idea where that one goes please if you know I'd love to know... Thanks
I was curious to know what you have mounted on the left front fender? I do like your video and will use it for reference when my starter goes bad. Thank You,,,
I went ahead and ordered a new starter test solenoid with a multimeter and the solenoid was fine I went and even used a battery that I knew was good and same thing it I turned the key and I tried it for about 3 seconds the it went click click click again
Hey Brother question? my polaris trail boss, stars with the pull start only when I try to start it with the key it only clicks I have change the solenoid but I can't get it to start with the key ..... the only way to start it. is with the pull start this it mean that i have a bad starter......
I am sure by now you have gotten it fixed, but I just currently had the same problem, I am actually putting clutch and plastic back on tonight. My 07 500 sportsman was doing the exact same thing. Had a spare starter from a Trail Boss that mounted right up. First thing I would do when starter is removed is clean all connection points from starter to solenoid- solenoid to starter including grounds. I put new one on and it still clicked. cleaned everything and fired right up.
