Wouldn't even mess with rebuilding a starter now days.You can get them way too cheap for that. Plus I'd get the bendix with it. Problem is that you know the starter's on the bottom of the engine and a bear to change out. Some with good hands can get the starter brackets off,but since I had a good lift and air tools,I just ripped the clutch cover,clutches,backing plate and the starter bracket stares you right in the face.. Hopefully you still have the cover and clutch off.. You do have to remove the recoil and remove the two bolts that hold the starter there also. Then you can pull both starter and bendix out from the recoil housing. Better than having to pull the flywheel. Plus check out these starter options.250,300,400 all take the same starters. DB Electrical - 250 Plus several on ebay you can choose from..Polaris 250 starter | eBay

 

Well of course the covers and clutches are back on attached and all back together. I've heard from people just drill a hole through the cover to access one bolt they can't get at and then replace the hole with filler or whatever when finished, is that possible on my model of atv?

I'll order a new one this week and wait for it to arrive...

Greg

 

Drilling holes through the clutch cover backing plate to get access to the starter bracket would just be plain lazy!! Then you'd have to seal this up and hope you didn't get water into the clutches.. I'd rather stand the machine on its azz end like I had to do in the old days before I had a lift and work on it standing up rather than drilling holes in the backing plate. If you have the clutch puller do the job right and then you wouldn't have to worry about filling holes.

 

So after heading out on a morning ride this morning, I return back to the jeep and have zero electronics, no headlights working, no 4X4, and very dim lights on the gear selector if any lights at all. get home and battery is at 8 volts... I will also mention that I have handlebar and a thumb warmer installed and maybe they are drawing to much juice, although I'm not sure they even worked today because they didn't really even warm up today when I first started out on my ride today....

So perhaps it still needs a voltage regulator maybe? I cleaned up the connections that were rusty...so maybe thats the whole problem is the voltage regulator I'm not sure now. Is there a way to test it?

 

I will add that I didn't install those items, they came with the quad I just replaced the missing fuse and the warmers worked right away, but maybe too much draw on the system...

 

Make sure the hand warmers are hooked up to a red/white wire that's powered up only when the key is on to eliminate any draw. They still may be too much of a load for the electrical system especially at slow speeds. These old regulators didn't really charge until they were off idle to begin with. Even if the battery is fairly new I'd load test it if you haven't already to make sure it can even handle the charge from the regulator. 13.86 volts is fair,about what these old 150 watt alternators would put out.

 

ok thanks I'll have the battery load tested tomorrow for sure on my lunch break. I also removed the top cover and made sure the power was only on when the key was in the on position and it was wired correctly for the hand warmers

Is there a way to test the stator? I think I tried to measure the resistance and I just want to make sure...Also I noticed that both the yellow wire and yellow/red coming from the stator were plugged into the same block on the circuit board if that make sense.Although I noticed on the circuit board there was a spot for just yellow wires, since I noticed one yellow wire going to the voltage regulator. So I'm wondering now if that one yellow wire coming from the stator was in the wrong spot and that was the cause of my issues, I don't believe that one yellow wire belong in the block with the yellow/red ones...if that makes sense....

 

Wires in the wrong place on the circuit board can make a difference. Just make sure that yellow is a solid yellow as some wires may not have a visible stripe but a small series of small dots or slashes at different intervals. If you're sure plug it in the correct spade connector and recheck charging.