I am working on a 98 Big Boss 6x6 for a friend. The starter gear doesn't release from the flywheel after starting and the counter weights come loose. When my friend got this, it wasn't running. He got it running and notice a rattling noise coming from the right cover. He brought it to me to check out (I'm a Ford tech) upon removing the cover, it looks like several parts have been replace at some time (before my friend got it). Are their any known issues with these? Thanks

 

Starter and gear shafts (bendix) are cheap here if needed. DB Electrical - Polaris The gear shafts do wear out and can tear up stators if the counter weights fly out if the garter spring breaks. Rattling noise could be from the recoil assembly itself,make sure the recoil works properly,the ratchet lever kicks out and retracts and the bolt and cover plate are snug. Also rattling could be from worn gear shaft bushings in the recoil and engine case. Look here under "recoil starter" on your model and should show the assembly and bushing. Browse Hope this helps. OPT