I'm in the process of replacing my pull starter on my 1998 scrambler 400 4x4. When I first started I thought this would be an easy fix but it has turned out to be a pain in the a$#!! I removed all the bolts from the mag/pull starter cover except the lower left one. when I try and slide the cover off the lower left bolt hits the awd drive shaft. The only way now I can see to get the cover off is by removing the awd drive shaft, draining the trans fluid and taking the front cover with output shaft off of the trans! Anyone else experience this problem and have an easy fix?

 

Try some more. It will come off. Ihave never had to remove the drive shaft on one to get the cover off.

 

Well its not looking good, I've tired just about everything aside of cutting the bolt off, (my next resort). Someone must have put the wrong bolt in there because it is impossble to get that thing out of there. Is the lower left bolt on your scramblers shorter than the rest?

 

The lower left bolt is longer than the rest because it goes into the starter.

 

Hey!! The same thing happened to me. All I did was remove the front engine support nut then use a bar and pry up on the engine just enough to get your bolt out. it worked for me.

 

Thanks for the tips, I'll try again tonight with loosening the front motor mount and see what happens. This is truly aggravating for what should have been a simple job...

 

take it off at the engine or the frame, therwise you risk throwing your clutches out of alignment.

 

Hopefully you don't have to wined up the spring on the pull start, because sometimes that sucks.

 

Which bolt do I loosen now, the rubber one on the engine?

 

Theres two bolts that holds the engine mount bracket to the engine and a nut that holds the bracket to the frame (with the rubber piece). Remove the nut and then pull the mount off of the stud. After you have done this, the engine will have enough play to lift the engine a little in order to remove that pain in the butt long bolt.