i just picked up a nice 1994 polaris 400 liquid cooled 2x4, it has the body style of a trail boss, very good bike, but i'm having trouble with starter, it just clicks, i put new battery in and cleaned and checked all battery connections, is my starter bad? if so, can you tell me where it is located, and is it hard to replace? any input on this would be greatly appreciated.

 

The starter is located on the bottom of the engine - you will have to remove the skid plate to access it.

A service manual would be of great help in this project - and future projects also.

The starter has 2 10mm bolts on the rear support bracket connecting it to the engine - 1 is fairly easy to get to, the other is a royal pain and will take patience unless you remove the clutch cover, clutches, and inner cover.

After you get those 2 bolts out, then the recoil starter housing has to come off to access the front 2 starter bolts (there are actually 3 bolts holding the front of the starter in, but 1 long one is part of the bolts holding the recoil starter cover on)

Depending on the condition of the starter - you may be better off replacing the whole starter - you can get a brand new starter off Ebay for $132 with shipping.

 

thanks for your info, it is greatly appreciated