My 1991 Trail Boss 250 4x4 needs a new starter or a rebuild kit. But browsing ebay I see there are complete ones for $42+shipping, but they say 95 and up. But they look excactly the same as my 91. What's the difference? Can it be compatible?

Also, I would be happy with just a rebuild kit, all I need is the front bearing, brush assembly and seals, but there are only 2 brush style rebuild kit's, mine is a 4 brush style. The dealer want $80 for just the brushes and brush holder! Any other options? Thanks for any help guy's!

 

The only difference I can see, is that the 91 starter has 4 brushes and the 2 screw's that hold the motor together are exsternal. The 95 starter has 2 brushes and the 2 screw's are internal (pass inbetween the magnets).

The crank case that the starter bolts to, the starter gasket and the rear bracket that holds the starter in place all have the same part number for both the 91 and 95. And the ASM starter gear drive look's to be the same to.

I also see the part numbers polaris call's out are the same, they both now are 3085393. They both had the same old part number to, 3084403. I dont know how that can be when they were not identical.

Can some one confirm a 95 starter can fit a 91 motor?

 

It will fit.

 

<div class="FTQUOTE"><begin quote>Originally posted by: 94harley

It will fit.</end quote></div>

You done it your self or know of some one that has? Do you know why the ad's say 95 and up only? Also I'm guessing the $42 ebay starter is a made_in_china part, do they last for a few years at least?

 

If they both sub to the new number then dimension wise they would have to be the same. Some of the older starts had 4 brushes, newer ones had 2. But physical size was the same. Some starters had a drain in them and some didn't(which is enough for Polaris to change the part number) I worked a dealership for 15 years and every 2 stroke starter looked pretty much identical. it will work for you.

 

i have one of those 42 buck starters on mine for the last 6 months works great and the one i bought had a 1 year warranty. $42 is not that much i figure if it lasts a couple of years im not hurt.

 

Thanks a ton for the info guy's. There is a guy local to me that sell's ebay ATV starters, I can have one next bussiness day.

How much compression should the 250 have?

 

compression should be atleast above 100 psi.. but optimal is around 120-130psi

 

<div class="FTQUOTE"><begin quote>Originally posted by: eggenz7

compression should be atleast above 100 psi.. but optimal is around 120-130psi</end quote></div>
Looks like I have to remove the gas tank to get any kind of gauge in there hua.

I'm starting to think 2 stoke's hate me. I have 2 250's and they both do the same thing, they will start and run momentarily, then they will not start again. Both have strong spark and healty carb's with fresh gas. Float's are not sticken either, in fact the plug's get wet. But even if I let it dry out for a few day's and clean off the spark plug, they refuse to run again.