First i tried to not remove the starter without taking the clutch off. I took the bracket off and the two bolts holding it onto the starter. I can see one bolt on the top but can't get to it with a socket or wrench. So i decided to try to take off the driven clutch assembly. How do you get that thing off? I took out the six bolts holding the outside on, the spring, and the belt. Now how do i get the rest off. It doesn't really say in the book how to get it off. Is there a tool that i need to get it off? Do i turn it counterclockwise? I can't get it to move at all. I know that once i get it off i can get right to the starter. Thanks for the help.

 

You will need to purchase a special clutch puller designed for Polaris
clutches. The puller looks like a threaded bolt and to use it you remove
the center bolt from your clutch and thread in the puller. It helps if you
put some grease on the end of the puller prior to installing.

 

Thanks for the help 400bossman. How much do the pullers cost? Can i get one at the dealership? Does it just thread into the middle of the shaft? Do i have to have that spider removal tool or is that what it is? Thanks for the help.

 

Dennis Kirk has one for 33.99 or you can order thru your dealer.To use
you remove the center bolt from the primary clutch and then thread in
the puller. Tighten the puller with hand tools ,do not use an air impact.
You do not need a spider removal tool to remove the clutch. The clutch will come off as a complete unit. If your in good with your dealer and
have everything ready he would probably do it for free.It would only take
a few minutes.

 

I just did one last week, no abnormal tools needed.

1 - unhook the battery
2 - remove skid plate from bottom
3 - remove floor board from pull starter side
4 - remove pull starter cover
5 - remove nut & unhook wire on the starter
6 - remove 2 bolts from starter (inside pull starter assbly.)
7 - remove 2 nuts from starter with 10mm or 12mm (can't remember) from the back side of starter
8 - remove starter from engine, pull though the frame

The nuts on the bracket & removing the starter from the frame is a little tough but can be done.
One hint, don't try to remove or reinstall the starter with the bendix on. Do it in two different parts. Ie. (reinstall) put the bendix in place first, then put the starter in. Than insert the bendix into the starter.

Good Luck.

 

NewDslover, what kind of bike did you replace the starter on? I didn't realize i had to take off the recoil starter cover to get to the bolts that hold the starter in place. I thought there were 3 bolts on the back side of the starter. I couldn't get behind the back side of the starter to remove the large top bolt. I just got a clutch puller so i am going to try to take off the clutch and pull it out. Do i have to take the recoil cover off? Thanks for the help.

 

DSLOVER is right, I had to do my Xplorer starter not too long ago. It can all be done from the pull start side, no need to touch the clutch side. Just my two cents.

 

Is the starter on the bottom of the engine like the 250? If so, then it can be removed and installed without pulling the clutch. The rear bolts are difficult but doable.

 

Total of 4 bolts and the power lead nut. 2 bolts on the back side of the starter and 2 bolts on the inside of the pull starter.

You don't need to pull your clutch to remove your starter. The quad was a 97 400 2 stroke Explor.

 

Thanks for all your help guys. I bought a primary and secondary clutch puller but it was not needed. It was very easy to get off after i removed the recoil starter. My starter was full of mud and water. There were no brushes left at all. I cleaned it out with electronic parts cleaner and blew it out with compressed air. I then used rtv to put around all the seals. She fires right up now. No more pulling. Installation was easy.