2002 Sportsman 500 Ho

[H.O.B.L.]

I noticed a grinding noise coming from my bike while I was riding, I pulled over and figured it must be the starter drive assembly stuck in the out/start position. I shut off the bike and when I tried to start it again, I got grinding noise worse than before. I removed the recoil housing and found the start drive assembly cogs all torn up, flywheel was OK. I then found 6 pieces of what I can only assume to be graphite, part of the starter drive assembly I assume, the parts manual calls it the Gear Shaft Assembly PN 3087030.
What I have found so far is this. The starting motor is OK, I can also turn over the engine with the pull cord, but it will not start, sounds like good compression. I am assuming that the graphite pieces may have caused a problem with my Stator; I need to check for spark.
I need to know, how can I pull off the flywheel with the puller if the flywheel keeps turning over?
If I pull off the flywheel have I got to replace the timing key with a new one?
A chip is taken out of the Pulser Coil, have a got to get a new one.

[superchicken]

well when I take off a fly wheel I either have made a puller varying on type or buying one meant for the type of quad...If it spins on ya wile trying to turn the puller, use a strap wrench...or if its small enough a large oil filter wrench..On a gear driven tranny u can just have a buddy sit on the quad with it in gear with both brakes on to keep it from spinning..

woodruff key....check it out once you get it off..most times they stay seated in the slot on the crank and dont need to replace...

[motorhead]

<div class='quotetop'>QUOTE (superchicken @ Aug 10 2006, 06:39 PM) <{POST_SNAPBACK}></div>

well when I take off a fly wheel I either have made a puller varying on type or buying one meant for the type of quad...If it spins on ya wile trying to turn the puller, use a strap wrench...or if its small enough a large oil filter wrench..On a gear driven tranny u can just have a buddy sit on the quad with it in gear with both brakes on to keep it from spinning..

woodruff key....check it out once you get it off..most times they stay seated in the slot on the crank and dont need to replace...[/b]

Strap wrench is a good idea but if you or know someone with an air compressor and an impact gun it will be easier yet. A couple burps of the gun and it will be off.

Is there a hole in the flywheel that you can slip a punch to lock it up???That may work too.

[H.O.B.L.]

Hey,

I got it off using an impact gun, thanks. I see that my Stator is OK from the visual inspection, I need to check my Pulser Coil, it looks in hard shape due to flying sebris from Starter Gear Assembly. How can I check the operation of this Pulser Coil, what does it do?

[motorhead]

<div class='quotetop'>QUOTE (H.O.B.L. @ Aug 11 2006, 06:20 AM) <{POST_SNAPBACK}></div>

Hey,

I got it off using an impact gun, thanks. I see that my Stator is OK from the visual inspection, I need to check my Pulser Coil, it looks in hard shape due to flying sebris from Starter Gear Assembly. How can I check the operation of this Pulser Coil, what does it do?[/b]

If you have a shop manual there is probably a resistance spec on it and it should tell you which wires to check it on??? if it looks banged up I suggest replace it.

[H.O.B.L.]

Thanks to everyone for the help. I broke down and bought a compressor and service manual. I have replaced the Starter gear assembly and pulser coil. Checked the specs on everything, changed all the fluids, filters and lubed everything up, new spark plug and she started on the first turn of the key.