1995 Polaris starter removal
#1
iM GETTING READY TO TEAR INTO MY 1995 POLARIS 400 AND REMOVE AND REPLACE THE STARTER. iM SURE ITS THE STARTER, BUT NOT SURE HOW TO REMOVE IT. CAN SOMEONE GIVE ME A DETAIL DESCRIPTION ON HOW TO REMOVE IT? Any tricks how to get to it out with out removing clutches </u></u>tHANKS A MILLION
#2
It can be done without removing the clutches but there is one bolt that you probably won't be able to reinstall. It is on the bracket that holds the rear of the starter in place. There is actually two bolts there and one is easy but the other one is almost impossible. I usually dont bother with it and leave it out, never had any problems yet.
Remove your pull starter first, there is 1 or 2 bolts in there that hold the front end of the starter.
Disconnect battery cables and remove battery.
Tip the bike up on its rear rack. (watch out for fuel or oil leakage out of vent lines/ caps)
Remove skid plate to expose the starter.
Undo the starter cable on starter.
Remove 2 bolts that hold rear bracket on starter and 1 bolt at front of starter and remove the starter.
Remove the bracket from the starter.
Reverse the procedures to reinstall new starter.
Also clean and lube the starter drive (bendix) while you have it out and make sure you use a new gasket on the starter and sealant on the pullstarter flange. Moisture inside the starter is the biggest cause of failures.
Remove your pull starter first, there is 1 or 2 bolts in there that hold the front end of the starter.
Disconnect battery cables and remove battery.
Tip the bike up on its rear rack. (watch out for fuel or oil leakage out of vent lines/ caps)
Remove skid plate to expose the starter.
Undo the starter cable on starter.
Remove 2 bolts that hold rear bracket on starter and 1 bolt at front of starter and remove the starter.
Remove the bracket from the starter.
Reverse the procedures to reinstall new starter.
Also clean and lube the starter drive (bendix) while you have it out and make sure you use a new gasket on the starter and sealant on the pullstarter flange. Moisture inside the starter is the biggest cause of failures.
#3
Save the headaches and spend $25 on a clutch puller.You will find you will use it more than you think.
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