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1998 Xplorer 300 4x4 starter removal

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Old Oct 15, 2012 | 10:43 AM
  #1  
Fulmer's Avatar
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Trailblazer
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From: Harrisburg, PA Area
Default 1998 Xplorer 300 4x4 starter removal

I recently removed the starter from my daughters quad and thought I would post as it was a pain and I could not find info on removal. Disconnect battery. I removed the clutch cover since the inner seal on the clutch cover was cracked and needed replaced. Removed drive clutch using a 3/4" diameter, 6" long, fine thread bolt. Driven clutch was much more difficult since it would not simply slide off the splines. Could not find anywhere a 1" diameter, 2" long, #12 fine thread bolt to use as a puller. Tried a trailer ball hitch and several 1" fine thread bolts I had around, but none would threadin. I wound up buying the puller off Ebay for $19. When receiver the puller was too long and I could not start the threads. I had to cut 1/2" off to thread. Removed few bolts holding inner plastic clutch cover.

You now have easy access to the starter. Removed line from battery. Remove skid plate. Remove 4 bolts on bracket mounted to starter and engine. Remove fly wheel cover, bottom bolt is a pain do break lever arm. Remove the 4 bolts on this bracket. Good Luck
 
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Old Oct 15, 2012 | 11:16 AM
  #2  
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From: North Texas
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You actually did it the easiest way,but like you said it's still a lot of work replacing starters on the 250,300 and 400 atvs. I always pulled the clutches and backing plate to gain access to the starter bracket bolts also. I tried years ago standing the machines on their tail ends,removing the bash plates and fighting to get the back starter bracket bolt out! Just a big pain especially if you have big hands. Congats on the job,plus your post just might convince others this is the best way rather than fighting it. OPT
 
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