How to I get the Starter out ('00 GP800)

[vbvhokie]

My wave runner won't start - just clicks. I've eliminated the battery and starter relay. I'm trying to get the starter out and I am stuck. I've removed the hot cable and both rear bolts (including attached ground cable). Now I can move the starter up and down just a little, but I can't get the starter loose. Am I missing something? Is there some technique I need to use, Or do I just need to muscle it out of there. (Not much working room at all!) I've already busted the same knuckle several times and I'm frustrated enough to start some serious banging and prying. But I thought I'd post here first and get some advice before I started something I might regret later.

It's a '00 Yamaha GP800.
Thanks,
Mark

[1fastski.com]

Re: How to I get the Starter out ('00 GP800)

its held in with 2 Orings and crude lol you can tap or pry it off just be very carfull that you do not break the cone off in the block .

[skraggy]

Re: How to I get the Starter out ('00 GP800)

The nose will break fairly easy if pryed or angled too much.

Has the starter ever been replaced ? If so,I have had problems(with 1200npv) with the aftermarket starters not clearing the case web that sits behind the starter.It will clear it,but you have to angle it just right while pulling it outward.Then it will just drop right back in easily.May be the same in your case.

If it is the stock starter(or aftermarket)...They tend to get some buildup where it slips into the case(where the o-ring is) sometimes.If you feel that it is bound and is not going to come out,you may have to pull the magneto cover,flywheel and bendix,and drive it out with a punch.You may have to do this anyways if the nose does break off just to get the broken piece out.On your motor,this is a pretty major job,so I would try everything possible to avoid pulling the mag cover.Maybe try getting it somewhat loose,soak it with some penetrating oil a few times,and try-try again.Technique=Wiggle lightly and pull hard.

good luck

[CTXL1200]

Re: How to I get the Starter out ('00 GP800)

Just to confirm - you removed the larger bolts (12mm?) that bolt to the case, not the two smaller ones that hold the starter motor together?


If so, it can be stubborn, but it will come free....with a couple more knuckles missing!

[vbvhokie]

Re: How do I get the Starter out ('00 GP800)

Thanks for all of the feedback. Looks like more grunting and cursing are in order before I resort to prying and banging. (well now that I've been away from it for a little while I can say tapping instead of banging). Again I appreciate the guidance. It is comforting to know I'm that I haven't missed a retaining clip or something berfore I start straining on this one. -- I may need a bilge pump to get the sweat out of the hull after this job.

Thanks Again
Mark

I'll report after I get a change to try again!

[vbvhokie]

Re: How do I get the Starter out ('00 GP800)

Victory is mine!

I managed to wiggle and push the starter free. I found it easier to push the starter from the front than try to pull it. I just kept pushing from the front as I wiggled the back of the starter up and down. It took about 5 minutes of concentrated effort, but no more busted knuckles and not too much sweat - just patience.

I appreciate all of the advice.
-Thanks much-

It turns out the problem with the starter was the brushes were frozen in place. I cleaned up the brushes and commutator and the starter tested okay.
Installation was much smoother than removal.

Thanks again - Mark

[skraggy]

Re: How to I get the Starter out ('00 GP800)

NP...Glad to hear that it went OK