P500 How to: P500 Starter Replacement

[ehart814]

Well after some intermittent starter issues, she finally bit the dust.

This is a hard one boys, so stay with me!

Step one- get new starter

Remove old starter. It is accessed through the drivers side of the machine. It might be a bit easier if you remove the drivers side rear wheel, but it’s not needed.

NOTE: you will need to reuse the nut that holds the starter wire to the starter terminal. Do not remove the new nut that comes on the new starter - the wire goes over it.

Two bolts hold the starter in. You need a 12mm socket or wrench. Remove the bolts. One of them is also holding a ground wire. Then use a 10mm socket to remove the nut holding the hot wire to the terminal on the starter.

Move the wires out of the way and start yanking on the starter. It won’t be eager to come out. You can stick a screwdriver under the ear (where the bolt goes through) and pry while wiggling it. Eventually the old starter will come out.

Pic of where the starter was:



Now take your new starter and put some grease on the Oring.


Stuff it in the hole!



Replace the bolts, making sure to run the passenger side bolt through the ground wire...

Attach the starter wire to the terminal.



Start the machine and ride. It probably took me longer to type this post than to make the repair. Didn’t even take long enough to finish a beer.

Also, this job could be done on the trail if needed!


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[Admin]

 

[Chooglin]

Thanks for the write up , hopefully I will never need to refer to it.

 

[ehart814]

Thanks for the write up , hopefully I will never need to refer to it.

At least you know how easy it is now. And a new starter is only $60. I was expecting a much harder job, but it’s actually quicker and easier than an oil change!


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[500oneer]

Well after some intermittent starter issues, she finally bit the dust.

This is a hard one boys, so stay with me!

Step one- get new starter

Remove old starter. It is accessed through the drivers side of the machine. It might be a bit easier if you remove the drivers side rear wheel, but it’s not needed.

NOTE: you will need to reuse the nut that holds the starter wire to the starter terminal. Do not remove the new nut that comes on the new starter - the wire goes over it.

Two bolts hold the starter in. You need a 12mm socket or wrench. Remove the bolts. One of them is also holding a ground wire. Then use a 10mm socket to remove the nut holding the hot wire to the terminal on the starter.

Move the wires out of the way and start yanking on the starter. It won’t be eager to come out. You can stick a screwdriver under the ear (where the bolt goes through) and pry while wiggling it. Eventually the old starter will come out.

Pic of where the starter was:

View attachment 122436

Now take your new starter and put some grease on the Oring.
View attachment 122437

Stuff it in the hole!

View attachment 122438

Replace the bolts, making sure to run the passenger side bolt through the ground wire...

Attach the starter wire to the terminal.

View attachment 122439

Start the machine and ride. It probably took me longer to type this post than to make the repair. Didn’t even take long enough to finish a beer.

Also, this job could be done on the trail if needed!


Sent from my iPhone using Tapatalk

My starter sounds like a dentist drill is that what yours was doing?

 

[ehart814]

My starter sounds like a dentist drill is that what yours was doing?

No, mine just totally quit


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[HondaTech]

Not trying to say you did it wrong, as that seems to be the simplest way.

But for me, I remove the 8 bolts holding the rear rack on, remove 1 mud clip holding the air snorkel tot rear fender, unplug the taillight harness and remove the rack and fender in 1 piece.

Now you have all the room in the world to get that bad boy out.

 

[trigger]

Not trying to say you did it wrong, as that seems to be the simplest way.

But for me, I remove the 8 bolts holding the rear rack on, remove 1 mud clip holding the air snorkel tot rear fender, unplug the taillight harness and remove the rack and fender in 1 piece.

Now you have all the room in the world to get that bad boy out.

Yeah, taking the rear rack and fenders off is easy in its stock form but depending on what's been added to the rear? It's a full days job taking mine off and probably 2 days putting it back together. I'd opt for the wheel well access in my situation.

 

[Chuckie3]

Agree trigger,some of use have a lot of custom boxes on the rear racks

 

[Judge]

Followed your instructions and put in my new starter today. One tip.After you get the hot wire off (10mm) and the two bolts (10mm) i could not get the old starter out. No place to pry or grasp.I tied a piece around one of the "ears"that the bolts go through and pulled the rope out the back of the sxs. one tug and it popped right out

 

[BigRedMac]

Same thing happened to me....started just stopped about 2-3 weeks ago. But now after replacing it, it starts & runs, but the paddle shifters don't work? Any ideas?

 

[Alan aka Davinci]

This may help also.

 

[Yukon_Jon]

I recognize this is a two year old thread, but it just became all of a sudden very relevant to me, unfortunately. So thanks! Made things very straightforward. I was going to pull the whole rear off, as suggested elsewhere. But this is definitely faster. If a little more cramped

 

[CTRCME9]

Well after some intermittent starter issues, she finally bit the dust.

This is a hard one boys, so stay with me!

Step one- get new starter

Remove old starter. It is accessed through the drivers side of the machine. It might be a bit easier if you remove the drivers side rear wheel, but it’s not needed.

NOTE: you will need to reuse the nut that holds the starter wire to the starter terminal. Do not remove the new nut that comes on the new starter - the wire goes over it.

Two bolts hold the starter in. You need a 12mm socket or wrench. Remove the bolts. One of them is also holding a ground wire. Then use a 10mm socket to remove the nut holding the hot wire to the terminal on the starter.

Move the wires out of the way and start yanking on the starter. It won’t be eager to come out. You can stick a screwdriver under the ear (where the bolt goes through) and pry while wiggling it. Eventually the old starter will come out.

Pic of where the starter was:

View attachment 122436

Now take your new starter and put some grease on the Oring.
View attachment 122437

Stuff it in the hole!

View attachment 122438

Replace the bolts, making sure to run the passenger side bolt through the ground wire...

Attach the starter wire to the terminal.

View attachment 122439

Start the machine and ride. It probably took me longer to type this post than to make the repair. Didn’t even take long enough to finish a beer.

Also, this job could be done on the trail if needed!


Sent from my iPhone using Tapatalk

Thank you for the step by step on replacement of a bad starter. I must ask about how long did it take to remove old starter and install the new one. I decided to take my machine to a Honda sales/repair shop and I don't want to be charged for idle hours at $90 an hour. According to the manufacturing plant technicians it should take now longer than 2-hours for a novice to change it. Since I am new to this forum any and all information is a plus. Thanks again for your input.

 

[CTRCME9]

I joined the forum yesterday, 11June, I have had no idea what was available out here on the web, especially a forum like this. I live in NC, and purchased my P500 after joining a hunting club since the club parking area and hunting areas are about 1/2 mile from each other and I hunt the far back side. My grandchildren call the machine the big Red bike and love riding in it. My wife takes it out as often as she can. I think she has more hours in it than me. The P500 is/was a great choice for us. Glad to be a member here.🙂🙂

 

[Judge]

I tied paracord to the "ears" on my starter and yanked it out after removing the bolts

 

[PJ1]

After a recent washdown of a muddy p500 my starter is whining like a little b****. Was fine until I took the hose to it.
Wow can't say b****? b****.

 

[Labeef]

Well after some intermittent starter issues, she finally bit the dust.

This is a hard one boys, so stay with me!

Step one- get new starter

Remove old starter. It is accessed through the drivers side of the machine. It might be a bit easier if you remove the drivers side rear wheel, but it’s not needed.

NOTE: you will need to reuse the nut that holds the starter wire to the starter terminal. Do not remove the new nut that comes on the new starter - the wire goes over it.

Two bolts hold the starter in. You need a 12mm socket or wrench. Remove the bolts. One of them is also holding a ground wire. Then use a 10mm socket to remove the nut holding the hot wire to the terminal on the starter.

Move the wires out of the way and start yanking on the starter. It won’t be eager to come out. You can stick a screwdriver under the ear (where the bolt goes through) and pry while wiggling it. Eventually the old starter will come out.

Pic of where the starter was:

View attachment 122436

Now take your new starter and put some grease on the Oring.
View attachment 122437

Stuff it in the hole!

View attachment 122438

Replace the bolts, making sure to run the passenger side bolt through the ground wire...

Attach the starter wire to the terminal.

View attachment 122439

Start the machine and ride. It probably took me longer to type this post than to make the repair. Didn’t even take long enough to finish a beer.

Also, this job could be done on the trail if needed!


Sent from my iPhone using Tapatalk

Just did this starter swap. I removed the left back wheel and used my loader to lift the sxs up a few feet. This allowed my 74 year old body to sit on a crate and do the job. Only trouble I had was getting the new starter to seat all the way in the hole, the o ring offered some resistance so I installed the mounting screws and carefully tightened them a turn at a time to draw the starter in and seat it. Overheating was the cause of failure, the glue holding the magnets came loose and locked up the starter.

 

[Smitty335]

Just did this starter swap. I removed the left back wheel and used my loader to lift the sxs up a few feet. This allowed my 74 year old body to sit on a crate and do the job. Only trouble I had was getting the new starter to seat all the way in the hole, the o ring offered some resistance so I installed the mounting screws and carefully tightened them a turn at a time to draw the starter in and seat it. Overheating was the cause of failure, the glue holding the magnets came loose and locked up the starter.

What caused the over heating?

 

[PJ1]

Overheating was the cause of failure, the glue holding the magnets came loose and locked up the starter.

I think water is the issue dissolving the glue holding the magnets.

 

[Labeef]

No water involved, grand son was ridding around our property in low gears on a hot day (first time driving alone) and when he shut it off after 15 minutes of driving, I went to start it and the radiator fan came on and when I keyed the starter, only the click of the relay. Checked the coolent temp and it was high. Took the starter apart and many of the magnets were detached and were locking up the starter.
I use this machine everyday, year round on our farm so 5 years of use was a good run for the original starter