'97 XP 800 Starter keeps getting stuck

[Bob-ing]

I have an XP 800 97 that I bought off ebay. Go figure... The starter keeps getting stuck in the engaged postion on the flywheel and locking up the motor. This happens when you try and crank it over some times. I have replaced the starter with a new starter. Same problem. Do I need to replace my flywheel? Or, is it something else. Any ideas? If I have to do the flywheel do I have to remove the entire engine, or is it possible to pull it in the ski. It was a real pain pulling the flywheel off of my 96 XP when I replaced my block last summer and it was out of the ski.

[chadc]

Re: '97 XP 800 Starter keeps getting stuck

I had the same thing on my 98 XPL, I went through and cleaned all the grounds, and made sure they were on tight, took care of the issue for me.

[Bill O'Neal2]

Re: '97 XP 800 Starter keeps getting stuck

Is the new starter an oem starter and starter clutch gear, or aftermarket? I don't have this type problem using oem parts.

Typically, a low battery or bad grounds can cause this type of problem, as well as a rusty clutch.

You can pull the starter out without removing the motor, and you can pull the flywheel out too if you have the proper flywheel pulling tools. No need to remove the motor.

[Bob-ing]

Re: '97 XP 800 Starter keeps getting stuck

I'm getting good at pulling a starter. I can pull the starter and replace it in the field in about 5 minutes now. lol.

The starter is an aftermarket Aqua Torque. I have the original OEM starter still. Is there a special lube to use on the starter gear mechanism?

I have tried two differnet new batteries. I also leave all my skis on battery maintainers when stored in my garage. I agree, it does happen more often if the battery is low.

As far as the grounds they seem good also. I have had them all off and reattached snugly.

If I can avoid pulling the front cover off this engine, I'll be happy.

[Bill O'Neal2]

Re: '97 XP 800 Starter keeps getting stuck

You can buy a brush kit and commentator plate and repair the oem starter motor, about $35.00

If the oem clutch is good, use it. If not, buy a new one $85.00 or so.

I have had little luck using aftermarket starters and especially aftermarket clutches.

I lube my starter shafts with white lithimum grease or Bombardier grease.

It takes about 1.5-2 hours to remove a front cover and replace a flywheel, faster if you are in a hurry.

[1fastski.com]

Re: '97 XP 800 Starter keeps getting stuck

Aqua Torque is short for AQUA JUNK they last 15 to 20 min if your lucky i dont know why there suck scrap its ashame OEM starters are so over priced it would be nice to have a good low cost starter on the market .

you might want to pull your front cover and check for a broke or bent thooth and make sure you dont have debree flyin around in there you will damage your stator and pickup .