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  #1 (permalink)  
Old 05-19-2009, 09:39 AM
Weekend Warrior
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Join Date: May 2009
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Default Starter removal Xpress 300

Anyone remove the starter from a 96? Can anyone give me step by step removal? Ive heard of people removing from the top end, is this the easier way to do it? Thanks.
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  #2 (permalink)  
Old 05-19-2009, 10:11 AM
Pro Rider
2002 polaris scramblers
 
Join Date: Feb 2006
Location: cedar rapids ia
Posts: 392
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it has to come out the bottom

un hook the positive battery cable
remove pullstart assembly there are two hidden bolts inside pullstart by bendix
remove bottom skid plate
there are also 2 tight hard to reach bolts on the opposite side of the starter tucked up under the clutch cover and if your starter has never been out you may need to remove the outer clutch cover , both clutches and the inner cover to actually reach the bolts enuff to turn them
when all bolts are removed the starter should slide out the bottom. bench test it to see if it turns if not remove the end bolts to access the insides and clean and lube the gear and inspect/replace brushes
also inspect and lube the bendix
upon installation i leave out the top most of the hidden mount bolts and it make it alot easier next time by leaving the clutches alone
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  #3 (permalink)  
Old 05-23-2009, 02:11 PM
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Can someone tell me how hard or time consuming this is? I keep putting it off but times up, I need to get this fixed. Im a newbie to Quads, but worked on pretty much everything else, just hate to get into something over my head.
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  #4 (permalink)  
Old 05-23-2009, 04:01 PM
Pro Rider
2002 polaris scramblers
 
Join Date: Feb 2006
Location: cedar rapids ia
Posts: 392
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2 hrs with the right tools
your going to need the primary clutch puller for sure and most likley the secondary puller too other than that its basic tools and just time consuming, the way i figure it ,rip into it its not that hard if you have questions post them here or email me at raroethler@mchsi.com if all else fails ..then you can always pay someone to fix it but its pretty basic like i said

also if you have a decent polaris dealer nearby ,pull the clutch cover and pull up to the service door and ask the mechanic if he can use the puller or let you use it quick just to get the clutches off ... it can be done without removing the clutches but requires much more patients and a few good cuss words

good luck
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Old 05-23-2009, 08:55 PM
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Itch,
You say this can be done without removing clutches? Unfortunately I live in a town of 500, an hour away from anything that resembles a parts store. Ive got all the bolts out of starter except that one behind the clutch cover. All the rest came out reasonably easy. Did you use some special tool or way to get that last one out?
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  #6 (permalink)  
Old 05-23-2009, 09:09 PM
Pro Rider
2002 polaris scramblers
 
Join Date: Feb 2006
Location: cedar rapids ia
Posts: 392
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i lifted the quad into wheelie mode sitting it on the back grab bar so i could get a good look at it and used an end wrenck abot 1/12 of a turn ata time and got them out but removing the clutches is far easier if you have the pullers
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Old 05-23-2009, 09:09 PM
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Tags
300, 96, atp, atv, polarias, polaris, removal, remove, replace, starter, step, trailblazer, warrior, xpress, xspress



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