So, you're ready to head out for a ride, you turn the key, and nothing—just a clicking sound coming from your 2001 polaris sportsman 500 ho starter. It's one of those things that always seems to happen at the worst possible time, usually right when you've got the trailer loaded and the sun is just coming up. The Sportsman 500 HO is a legendary machine, but even the best workhorses have parts that eventually give up the ghost after two decades of mud, water, and trail dust.
If you've spent any time on an old Polaris, you know that the electrical system can sometimes be a bit finicky. When that starter motor decides it's done, you're left with the pull-start, which isn't exactly a fun workout on a high-compression 500cc engine. If you're lucky, it'll fire up on the first pull, but if you're like me, you'd much rather just hit a button and hear that engine roar to life. Replacing or fixing the starter isn't as scary as it sounds, but there are a few things you should know before you start tearing things apart.
How to Tell if the Starter is Actually the Problem
Before you go out and buy a brand-new 2001 polaris sportsman 500 ho starter, you really need to make sure that's actually the part that failed. I've seen plenty of people swap out a starter only to realize the issue was a loose ground wire or a dead battery cell.
The first thing I always check is the battery. These older quads need a lot of cranking amps to get that big single-cylinder moving. If your battery is sitting at 12.1 volts, it might turn the lights on, but it won't have the juice to kick the starter over. Give it a jump or a fresh charge first. If you hear a single "clack" when you hit the button, that's usually the solenoid engaging. If you hear a rapid-fire clicking, that's almost always a low battery.
Another trick is the "hammer tap." It sounds primitive, but if the brushes inside the starter are sticking, a light tap with a screwdriver handle or a small mallet while pressing the start button can sometimes jar it back to life. If it starts after a tap, you've found your culprit—the internal brushes are worn out, and it's time for a replacement.
The Bendix vs. The Starter Motor
One thing that trips up a lot of 2001 Sportsman 500 owners is the difference between the starter motor and the starter drive, often called the Bendix. On this specific machine, the starter motor sits on the back of the engine, but it doesn't directly touch the flywheel. It spins a small gear assembly (the Bendix) inside the recoil housing.
If you press the button and you can hear the 2001 polaris sportsman 500 ho starter spinning fast—like a high-pitched whirring sound—but the engine isn't turning over, your starter is actually fine. In that case, the Bendix is likely gummed up with old grease and belt dust. It's a common issue where the gear won't "throw out" to grab the flywheel. You'll have to pull the recoil cover off to clean or replace that, which is a different job entirely. But if the motor itself is dead silent or barely moving, then yeah, you're looking at a starter motor issue.
Choosing the Right Replacement Part
When you start looking for a new 2001 polaris sportsman 500 ho starter, you're going to see a massive range in prices. You can find cheap aftermarket versions on the big online marketplaces for about the price of a decent lunch, or you can go to a dealership and pay a couple of hundred bucks for an OEM (Original Equipment Manufacturer) part.
Which one should you pick? It really depends on how you use your quad. If you're just puttering around the yard or using it for light chores, a cheap aftermarket starter usually does the trick for a few years. However, if you're deep-woods riding or using the quad in freezing temperatures for snow plowing, you might want to spend a little more on a high-quality unit. The cheap ones sometimes struggle with "heat soak," where the starter won't work once the engine gets hot, which is a real pain if you stall out in the middle of a trail.
Getting Into the Wrenching
Replacing the 2001 polaris sportsman 500 ho starter isn't the most difficult job in the world, but it's definitely "tight." Polaris didn't exactly leave a lot of room to work with behind that engine block.
First and foremost, disconnect your battery. I can't tell you how many people have accidentally welded a wrench to the frame because they touched the live lead on the starter while trying to unbolt it. Once the power is killed, you'll usually find it easiest to get to the starter by removing the seat and some of the side plastics.
The starter is held in by two long bolts. Getting a socket on them can be a bit of a puzzle. You'll probably need an extension and maybe a swivel joint to get the right angle. Don't forget to check the O-ring on the nose of the new starter before you slide it in. You want a good seal so that moisture doesn't leak into the engine casing. A little bit of grease on that O-ring goes a long way in making the installation smoother.
Dealing With the Wiring
When you're pulling the old starter out, take a good look at the main power wire. Over twenty-plus years, these wires can get brittle or corroded. If the end of the wire looks green or crusty, trim it back and put a new terminal on it. A brand-new 2001 polaris sportsman 500 ho starter won't do you much good if the electricity can't get through a bunch of corrosion.
Also, check the mounting surface. The starter grounds itself through its body to the engine block. If there's a bunch of oil, dirt, or rust where the starter meets the engine, it might not get a good ground. I usually like to take a bit of sandpaper or a wire brush and clean up that mounting area until the metal is shiny. It ensures the motor gets all the power it needs to crank that big 500 HO over.
While You're in There
Since you're already elbow-deep in the machine, it's a great time to check the starter solenoid (the little relay that the battery wire goes to). These things are notorious for failing on older Polaris models. If you've replaced the starter and it still won't turn over, the solenoid is usually the next suspect. They're cheap and easy to swap out, so some people just do both at the same time for peace of mind.
Also, take a peek at your battery cables. If they're original from 2001, they might be toast. Replacing them with thicker gauge wires can actually make your 2001 polaris sportsman 500 ho starter spin faster than it ever did before. It's one of those "cheap wins" that makes the quad much more reliable.
Closing Thoughts
Fixing a 2001 polaris sportsman 500 ho starter is just part of the deal when you own a classic ATV. It's a bit of a chore, and you'll probably lose some skin off your knuckles trying to reach those mounting bolts, but it's worth it. There's a certain satisfaction in hitting that button and hearing the engine fire up instantly without having to break your back on the pull-start rope.
Once you've got the new motor in and everything bolted back together, give it a few test cranks before you put all the plastics back on. There's nothing worse than finishing a job only to realize a wire popped off. But once it's humming, you're ready to get back out there. These old 500 HOs are tanks, and with a fresh starter, your Sportsman should be ready for many more miles of whatever you can throw at it. Keep the battery tended, keep the connections clean, and you won't have to worry about that dreaded "click" for a long time.