Thanks for a good video, glad you got your starter fixed, hope it all worked out for you and you got the machine running. Just a couple notes (which you probably already know now): You do NOT have to drain the oil. Just raise the side of the ATV up about 4 inches / put a couple 2x6s under each wheel on the left side, and you won't spill a drop. I'm not sure what happened with the terminal on the motor, it should have 2 nuts on it and is not supposed to turn, something must have broken loose inside the motor. Putting the starter gear back on the starter is a snap with the side cover removed, it just slides right on. Cheers! Bellarmine
Richard Piles. What a great idea you posted about putting the atv on it's side. The last thing I wanted to do was take off the left case cover off.....what a pain. I drained the gas and with some help from my son and the wife got it resting on it's side. The original idea was to lay it over onto some jack stands placed under the front & rear racks. This did not make it flat enough and the sprocket would still slide out of position. It takes about 9" of blocks to get the sprocket to stay centered in place and then like you said the stater just slips into place. There is another video out there where the guy just undoes the two starter bolts and the two long bolts that hold the starter together and takes off the back half of the starter and if your problem is just brushes you can replace them without taking the entire starter out.
LOL..easiest way to change the starter is turn the bike on its side so the gear stays center then just put your starter in you dont have to take your starter apart
Great info.im workn on a locked up motor.it has oil in crank case. Also I pulled the starter when I noticed there's NO GEAR IN VIEW. Do u think its possibly that it dropped down by the crank and is logded somewhere in there.
HI THERE JUST HAD THE SAME PROBLEM BUT FOUND OUT YOU CAN LEAVE THE SPROCKET IN AND SPLIT THE MOTOR JUST TAKING OUT THE MOTOR ITSELF IF THAT MAKES SENSE THEN ALL YOU DO IS SLOT THE MOTOR BACK IN BUT I AM NOW ALSO GOING TO HAVE TO TAKE OFF THE SIDE COVER UHHHHH !!!! THERE IS A CHAP WHO HAS DONE A VID ON THIS SYSTEM I THINK ITS CALLED CHANGING A STARTER ON A KLF THE EASY WAY ????? ANY WAY THANKS FOR SHARING YOUR VID WITH US FOLK IT ALL HELPS DID YOU HAVE ANY PROBLEMS APPART FROM THE MAGNETS ON THE SIDE COVER REMOVAL ???? IE ANYTHGING TO WATCH OUT FOR COS WHATEVER I TOUCH I END UP WITH ANOTHER PROBLEM.. CHEERS ALLAN PS IS THERE A TENSIONER ON THE STARTER CHAIN ????
Excuse the screw that holding the piece,you take it off with the air gun, which way turn the screw to remove it. Right or left? the piece you show in 0.45 secons in the video
+Joel Alejandro Counter clockwise, left, used the air gun because the engine turned when I tried to take it off and I didn't want to damage the piece by holding it with a big screwdriver.
Tim Johnson - It has been some time ago but I did not use a torque wrench during any of the reassembly, probably just made it tight as I do recall it came right off with the impact gun
Derek Smith - Counter clockwise, left, used the air gun because the engine turned when I tried to take it off and I didn't want to damage the piece by holding it with a big screwdriver.
If you mean the starter clutch, it is behind the flywheel. You need a big metric bolt to 'push' off the flywheel, and then you will see a whole bung of little 'teeth' in a ring that grips the flywheel when you crank the starter. Anything else let me know - cheers! Also see here: fiche.worldofpowersports.com/wps/showmodel.asp?Type=13&make=kawasakiatv&a=21&b=46&c=0&d=-STARTER-MOTOR/STARTER-CLUTCH-%28E.-NO.-0176-AND-UP%29
+Danny Bresciani Got it all hooked up yesterday, new voltage regulator, new starter selenoid, new battery, starter turns like a champ but engine won't start.... have the carb off now for cleaning, will check some other things and hopefully have it running soon.
