My starter is burnt up and I am considering replacing it myself. Is this a hard task or pretty straight forward? What all is involved?

Thanks!!

 

Is it a 400 or a 500? The 400 I can help you with. It has the starter on the bottom of the engine. I think the 500 is different.

 

I replaced mine on my 96 Xplorer 400 about a month ago & I posted the process here for people to view. Now . . . mine is non-concentric, but it wasn't overly difficult. Just search my name (Loyal) and I think the post was entitled "Starter Problems". If you can't find it I think I have it saved in Word. I can repost or e-mail.

My dealer was going to charge me 3hrs at $40 plus $75 for parts PLUS tax. Well I changed mine in about 2.5hrs (first time doing it) and went to a starter rebuilding shop and got it rebuilt (with 6 mo warrenty) for $70.

 

This is the starter on the 400cc 2 stroke engine. Any help would be appreciated

Thanks

 

For those who are interested in saving a few bucks with removing their own starter when it gives problems . . . here is the process I used last night. 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 would first like to thank everyone who gave me their two cents worth. 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
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.
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.

 

Thanks, sounds like this is pretty easy to do. Might be awhile before I do this, been riding all the time lately. Just purchased my Scrambler and love it, 3 of my friends also have them. Bought one after riding theirs!

 

Remember that this is the process for a 96 Xplorer 400 that has chain drive. Yours may be a little different, but this is basically the process I used. Good Luck.