It sounds like you have a connection issue, and the starter eventually starts spinning erratically or just slowly. If the issue was at the relay or relay connections, a new relay may have helped temporarily. You need to go through all your wires, connectors and ends, and make sure everything is sanded, tight and corrosion free.
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engine lock up??about to sell this 97xp
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Well looking at the starter there was a allen screw that was left off.The two that mount to the upper flywheel were there but the rear allen screw was missing near the pos battery cable was missing and I looked at the threads that were supposed to line up with rear starter support and they didnt line up ,could this cause my original problem of my starter hanging up locking up?
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If you are talking about the bolt that goes in behind the end of the starter motor and bolts to the engine case, it is there to eliminate the viberations of the starter motor and to help support the weight of the starter motor. It probably is not the reason that you are having problems starting your motor. With or without that bolt, the starter will be aligned if the two bolts into the mag housing are in there and tight.
What that rear bolt does do, is prolong starter motor life, by reducing the viberations that will eventually cause the brush cables to break off inside of the starter motor.Bill O'Neal WCM
<a href="http://www.watercraftmagic.com" target="_blank">www.watercraftmagic.com</a>
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