i went to start my tb the other day and it would not start ...after charging the battery all i get is a click any ideas? starter jammed? or are there other things i should check? if it is the starter could i get a run down of removal steps? it looks like i'll need to remove the pull start and the cover behind it and the plastic and maybe a clutch or 2 on the other side...any info ,tips would be great thanks

 

check the solenoid w/ a jumper wire, and jump the starter directly, bypassing the solenoid.
Also clean all the connections at the battery, starter and solenoid.

The starters are a biatch to remove, at least on the 400s.
I would recommend the service manual.

Jim

from another post on the 400 scrambler....


My dealer was going to charge me $120 (3hrs @ $40) + $70 parts to fix the starter. I will be taking mine to a local alternator/starter repair shop who will charge me $75 to repair the starter. I have brought all the info together and added some of my own experience to come up with a process that should be quite attainable for the everyday backyard mechanic.

Starter removal (actual)
1) Securely raise the quad off the floor. I run mine up on 4 car ramps.
2) Remove seat and plastic side panels
3) Remove floorboard to get access to the recoil housing
4) Disconnect battery ground cable
5) Remove pipe. There is only three springs and one bolt and it gives you so much more room to play with. If you can get the Master Link out of the middle chain (I have a 96) do it, it will allow you to easily complete
Step 6 - but it is not necessary
6) Remove recoil housing. I found mine a little stuck so I had to tap it with a rubber mallet. It is still stubborn, remove the airbox and tap it from behind with a stick.
7) Remove the two starter bolts. I could not totally remove my recoil housing, but I shifted it to the right allowing me to gain access to the starter bolts.
Note: I discovered later that I could have removed both middle sprockets & chain to get easier access. (4x4)
8) Remove rock guard from the bottom of the quad
9) Remove starter cable.
10) Use 10mm wrench (long handle would make it easier) to remove the two short bolts attaching the starter support bracket to the engine
11) The starter should then slide out of the recoil housing through the bottom of the frame. Starter Installation (theory)
1) Loosely assemble support bracket to starter. Bracket bolts must be loose as to allow installation of support brackets to engine bolts.
2) Install new gasket (Part 3085283 Ref #18 Grid #D11) and place the starter in place
3) Steps 11-1 above.

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-Probably the easiest way is by removing the clutches and covers to get at the rear bolts.
-Remove the recoil and the 2 bolts inside and your wire and its off.
-You can take it off without removing the clutches, but its a real pain to put back.
As for what a dealer would charge, its hard to say for the guys around you.
We generally have about $65-75 for pulling it, cleaning, rebuilding, and reassembling + parts.


ps: don't forget to check the starter drive (bendix), make sure its free in one direction and the spring is still around the weights.

 

I agree, make sure you turn your key on first before jumping the solinoid. Somebody sells them new for $19 on ebay. More than likely that is your problem.

 

thanks for the info...i was hoping that wasn't the case but you know how that goes...

 

hey ...good news...yesterday i sprayed wd40 into the drain hole in the starter(i'm not sure if that really did anything or not) ,this afternoon,after i read you're replies, i hooked a battery charger ,in the start mode,to the negative battery cable and the other to the starter at the positive,at first it just buzzed ,then after 3-4 tries i heard a slight grind,like it was rusty and just like that fired right up...sweet...thanks again