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  1. #1

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    Wink I broke the starter off in the Block. What Now?

    1996 Polaris SL 700

    I just got the ski and the starter had power but would not turn at all. Tried tapping it and still nothing. So I took off all the exaust and tried getting the starter out. Took out both mounting bolts and the power cable. It would not budge. Soaked it with lubercant (pb blaster).The starter had corrosion all over it. I tried wiggling it for ever but would not move at all. So I got pry bars, still would bearly move. Lastly I got out a hammer and tried to hit the starter out while prying it out at the same time, and after like 50 hits the starter broke off completly and now the nose piece/bearing is stuck in the block.

    Any ideas????

    My only thought is to maybe heat it up with a torch,, I only own a small butane torch so I dont even know if that will do anything...?


  2. #2
    Click avatar for tech links/info, donation request K447's Avatar
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    Welcome

    You may need to open up the flywheel housing, remove the flywheel and Bendix, and drive the starter motor remains out from the front side.

  3. #3

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    I figured that is how I would have to access the broken piece. Is all that hard to do?

    Any ideas on how to get it unstuck though? I hit it a little with a hammer (to try and break it loose) and it still will not budge, all the while im soaking it with lube...

  4. #4
    Click avatar for tech links/info, donation request K447's Avatar
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    Removing the flywheel is the hardest part, once you get access to the front of the engine.

    Sometimes you need to shift the fuel tank forward to get working room, or even remove the fuel tank.

    Other guys find it easier to pull the engine right out of the hull, and do battle on the workbench.

    Search for flywheel puller

    Have you clicked on the links below?

  5. #5

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    I clicked the links, great info!

    I was hoping I could get it unstuck then simply pull it out the front.

    If I pull the flywheel and all that I still dont know how I will get it unstuck. I would prob just get the hammer out again and thats how this all started...

  6. #6
    Click avatar for tech links/info, donation request K447's Avatar
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    Use a drift and drive it towards the back of the ski, hammering from the front.

    Just don't crack the flywheel housing, or you will be buying another. That would be your plan B

  7. #7

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    Thanks for all your help on this!!

    What is a drift?

    Did you have an opinion on heating the flywheel case around the starter piece? I think that would make it expand and should (in theroy) allow me to get out the stuck piece?

  8. #8
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by schlik83 View Post
    ...What is a drift?

    Did you have an opinion on heating the flywheel case around the starter piece?

    I think that would make it expand and should (in theory) allow me to get out the stuck piece?
    A drift is a metal pin that you use to hammer something that doesn't want to move



    Be careful with heat. If you cook the rubber crank shaft seals that are right behind the flywheel, then you will be taking the whole engine apart.

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