I am helping a friend with a problem on his 2004 Kodiak 400 4x4. The starter makes a awfull sound but turns over the engine. The engine will barely start and stay running. When the regulator or 3 wires from the magneto are unplugged the starter sounds ok and engine will start and run normal but will not charge. Then yesterday the starter would not engage at all. The drive splines on the starter are worn. We pulled the right engine cover to inspect the starter drive gears and all looks normal. Any ideas? Thanks

 

Sounds like it might be time for a new starter. Weird that it stops when you disconnect the stator...