2004 sportmans doesn't always engage flywheel

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  #1  
Old 03-16-08, 06:01 AM
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2004 sportman 500 atv doesn't always engage flywheel

i thought maybe the solenoid, replaced it. then the starter, replaced it. then the starter drive, replaced it. then the battery, replaced it. same problems. any advice?
 

Last edited by harrietlk; 03-16-08 at 06:11 AM. Reason: need better title
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  #2  
Old 03-16-08, 06:57 AM
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Did you take a good look at the teeth on the flywheel when you had it apart? Is the any spacers or shims you could remove to get starter drive to engage deeper? Battery good & strong? Check starter too as I have seen on occassion where the throw of the drive can be adjusted slightly, by removing a shim or small washer at the end where the drive travels on start. Double checked you alignment?
 
  #3  
Old 03-16-08, 08:11 AM
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When you say the starter doesn't engage is it spinning or just won't turn the engine over?

Given all your starter components are working well, I would say Mike in on track with it. Either your starter is out of alignment or the teeth on the flywheel are bad. On that type of engine it's more common to have messed up flywheel teeth. I can't say I've seen a lot of shims on those starters.

I think I would pull the starter, ground the case and hit your start to see if the drive is running all the way to the end of the casing. If it is, then back to the flywheel teeth and alignment of the starter.

Hope this helps,

Bob
 
  #4  
Old 03-16-08, 12:44 PM
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ty for the response

Originally Posted by marbobj View Post
When you say the starter doesn't engage is it spinning or just won't turn the engine over?


Bob
tks. i pulled the recoil off again, the teeth on the flywheel look fine, but i did see the bendix bound and not releasing back down. possible the bushings in the housing worn? there is play side to side. thankyou very much for your help, jay
 

Last edited by harrietlk; 03-16-08 at 12:45 PM. Reason: added ty
  #5  
Old 03-16-08, 12:48 PM
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Originally Posted by Mike.B View Post
Did you take a good look at the teeth on the flywheel when you had it apart? Is the any spacers or shims you could remove to get starter drive to engage deeper? Battery good & strong? Check starter too as I have seen on occassion where the throw of the drive can be adjusted slightly, by removing a shim or small washer at the end where the drive travels on start. Double checked you alignment?
thankyou for your reply, i did pull the recoil off again, the teeth on the flywheel look good, but i did find the bendix bound and not releasing back down. possible worn bushing in housing? there is some side to side play. pls respond, thankyou very much for your time and advice. jay
 
  #6  
Old 03-16-08, 12:51 PM
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Bad bushings don't help. Sometimes the starter shaft gets gummed up a little. A little penetrating oil loosens the bendix slide and gets you going again.

Later,

Bob
 
  #7  
Old 03-16-08, 05:37 PM
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Originally Posted by marbobj View Post
Bad bushings don't help. Sometimes the starter shaft gets gummed up a little. A little penetrating oil loosens the bendix slide and gets you going again.

Later,

Bob
bob,
starter, starter drive, solenoid and battery have all been replaced. i'm taking the recoil which holds one of the bushings and the shaft of the starter drive into a dealer tommorrow and see what they say. tks. jay
 
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