I'm a poor man's mechanic. My "95 300" is virtually a clone to "this." Didn't need to remove foot rests. The "50" cent sized piece that the spring is attached, front, I took my disc grinder and cut a small piece of it away to access the bolt behind it with 1/4 drive socket. Didn't need to remove brake lever. After having the two main bolts for starter out, I had fits cause I thought the starter should move left/out much easier. After losing hours of sleep over this, I tapped it with a small hammer and it rolled over and out! HalleluYAH. That, as an ending to this vid would have been appreciated. BUT, no matter, I wouldn't have been able to tackle this without your help Brad. Thanks much!!
That's hilarious! I'm currently, right now, sitting inside and had the exact same idea! Glad it worked. My God this project started with a belt replacement. I went ahead and fixed the brakes and everything else I can touch. I have this thing in 100 pieces! Even worse my toilet inside the house about fell through the floor with my wife sitting on it! 😂😂😂! The only thing that kept her and it from falling all the way through was a joist and the pvc. They went down about a foot! No shit (pardon the pun). So I had to go into floor man/plumber mode. So obviously time has passed and I have to remember how to put the quad back together. Please wish me luck! Poor me.
Thanks for this, I got my 95' 300 explorer about half apart, just enough to expose the front portion of the starter and the starter isn't even engaged with the gears on the shaft. It also wiggles around, I'm no expert, but I'm guessing that means it's worn out. Anyways, now I have to take off the second half and get her out. There's quite a few steps, I'd have been shaking my head and probably throwing a wrench or 2 had I not seen this, so thanks again!
I was able to remove the starter on my 95’ Sportsman 400 2 Stroke without having to remove anything from the left side. Your machine may differ from mine but I was able to crawl underneath mine and access the rear starter mounting bolts without a problem
I have my 300 apart. I cannot get enough clearance to get starter out. Perhaps if the gear cluster could be removed from the flywheel side it might. Did you remove flywheel?
Good video thank you But you do not need to remove anything on the clutch side of the machine!! After removing the pull start cover the rest is accessible from underneath with the skid plate removed and out of the way.
@@BrapStuff never mind I found a video of another Polaris 400 ATV that has the same engine they managed to get it removed without removing the clutch system this is because for me my primary clutch can't come off because of the thread's are all stripped out bad so I'm getting around it instead it's less of a headache for me to deal with
Dont listen to those guys about cutting the frame. With a little finesse it will come out. I took my 4 wheel chain off and you might have to take off the foot rest. A little patience and she`ll come
Sorry about all the questions it's my first ATV so there shouldn't be any oil under crankshaft and yes I do it is a true stroke I do have true stroke oil tank
Sounds like a person that has just looked at one and never actually worked on one. Obviously I could be wrong. You damn near have to rip it into 100 pieces to check the damn air in the tire. 🙄
It should not. If yours has oil, the crankshaft seal behind the flywheel is probably leaking. Get that fixed asap to avoid running the unit lean burning up the piston!
im no mechanic and learned you dont NEED a special tool to remove the drive clutch, just jump start her, rev. her a bit and watch that thing go flying!
I'm a poor man's mechanic. My "95 300" is virtually a clone to "this." Didn't need to remove foot rests. The "50" cent sized piece that the spring is attached, front, I took my disc grinder and cut a small piece of it away to access the bolt behind it with 1/4 drive socket. Didn't need to remove brake lever. After having the two main bolts for starter out, I had fits cause I thought the starter should move left/out much easier. After losing hours of sleep over this, I tapped it with a small hammer and it rolled over and out! HalleluYAH. That, as an ending to this vid would have been appreciated. BUT, no matter, I wouldn't have been able to tackle this without your help Brad. Thanks much!!
That's hilarious! I'm currently, right now, sitting inside and had the exact same idea! Glad it worked. My God this project started with a belt replacement. I went ahead and fixed the brakes and everything else I can touch. I have this thing in 100 pieces! Even worse my toilet inside the house about fell through the floor with my wife sitting on it! 😂😂😂! The only thing that kept her and it from falling all the way through was a joist and the pvc. They went down about a foot! No shit (pardon the pun). So I had to go into floor man/plumber mode. So obviously time has passed and I have to remember how to put the quad back together. Please wish me luck! Poor me.
Thanks for this, I got my 95' 300 explorer about half apart, just enough to expose the front portion of the starter and the starter isn't even engaged with the gears on the shaft. It also wiggles around, I'm no expert, but I'm guessing that means it's worn out. Anyways, now I have to take off the second half and get her out. There's quite a few steps, I'd have been shaking my head and probably throwing a wrench or 2 had I not seen this, so thanks again!
Thank you for the quick, clear, step by step to the point video.
I was able to remove the starter on my 95’ Sportsman 400 2 Stroke without having to remove anything from the left side. Your machine may differ from mine but I was able to crawl underneath mine and access the rear starter mounting bolts without a problem
Was your starter the same as this one because I have 95 sportsman 2 stoke also
Maurice Tanner it is identical to this starter on this Xplorer
Do you have the part number for the starter? I have a 1995 400 explorer
@@mf8913 I wished I did but I do not unfortunately.
I have my 300 apart. I cannot get enough clearance to get starter out. Perhaps if the gear cluster could be removed from the flywheel side it might. Did you remove flywheel?
Excellent video. Saved me a ton of time. Great details
Good video thank you
But you do not need to remove anything on the clutch side of the machine!!
After removing the pull start cover the rest is accessible from underneath with the skid plate removed and out of the way.
How do you renove the top bracket bolt? Doesn't work this way, atleast not on 98 xpress 300
I have a 96 express and you have to pull the clutches
@@itsridley8700or a 1994 300 2×4
if bendix is ok, should the starter just slide in and out from this side, mine seems stuck pretty tite , thanks for the video
What store did you get the 3/4-16X3 3 inch long bolt from?
Tractor Supply if you still haven't figured it out. Little late probably!
Thank you, you saved me a lot of time.
Great Video,,,, no BS just the facts PERFECT
What size and thread pitch bolt for the puller??
In the video description: Primary clutch puller bolt size 3/4-16X3 3 inch long bolt, 3/4" diameter, UNF Fine Thread 16 threads per inch.
On these 300s do I need to put it on top dead center before I install piston ?
Do you know what size bolt and thread you used when pulling the clutch?
It's a clutch puller that you have to buy, not a bolt.
The bolt is 3/4 x 11 the length I think is about 3 inches
Sorry its 3/4 x 16 the 11 was an accident
Isn't there any way around this without pulling the clutch system to replace the starter?
No sir!
@@BrapStuff never mind I found a video of another Polaris 400 ATV that has the same engine they managed to get it removed without removing the clutch system this is because for me my primary clutch can't come off because of the thread's are all stripped out bad so I'm getting around it instead it's less of a headache for me to deal with
Cool
Good luck. I don't recommend it!@@berad187
@@berad187I'm about to make an access door
Do all this just to replace the starter,? is it the same for 02 exp 400 ?
Should be yep but it's probably shaft drive to the front so that helps!
Awesome mate cheers
what size of rod did you use to pop out the starter?
Why would antifreeze start leaking when I loosened the bolts on the pull start.
Probably a bad water pump gasket or bad crankshaft seals. Im addressing this issue on my Xplorer right now.
I have a question about the starter
I wouldn't use an impact to do. Do u see the threads on the crank now? Buy the 20 dollar puller it will save u a headache
I have been doing this for YEARS and never had an issue damaging threads. For pulling the flywheel, BUY a puller -> I would agree.
@@BrapStuff I meant buy a puller for the clutch so u dont mess up the threads on the crank
I have never damaged crank threads with a bolt and rod. For pulling the flywheel, it's best to use a puller.
@@BrapStuff what size and thread is that bolt?
$70 cdn for these pullers, (royal distributing)
I just replace the head gaskets in my crankshaft doesn't have any oil inside of it I don't have motor oil filter or oil tank on mine is that normal
For a 2 stroke, there may be a 2 cycle oil tank and engine oil in the transmission.
How did u get the pull start cover off with out removing the engine, my cover keeps getting stuck on frame at bottom.
Hammer or cut the frame away or loosen the top engine mount.
@@BrapStuff cut the frame? where would i mount my rear brake lever?
Brap Stuff how do i install with the start gear sticking out, it gets caught on it
Dont listen to those guys about cutting the frame. With a little finesse it will come out. I took my 4 wheel chain off and you might have to take off the foot rest. A little patience and she`ll come
@@jameswaltz8473 yup ended up getting it, cutting the frame is crazy talk haha
Que medida es el dado para quitar el cluch
Sorry about all the questions it's my first ATV so there shouldn't be any oil under crankshaft and yes I do it is a true stroke I do have true stroke oil tank
You're correct. Also, the 400 does take oil for the crank-counter balance gears, but no oil should be in the combustion chamber.
How much oil does the crank Balance gear take
Not much - use the dip stick - roughly 4 oz or so.
Been nice if you told us what size bolt to buy. Saying “any bolt” from hardware store will work, doesn’t work obviously
It would be nice if you looked at the description below the video... OBVIOUSLY it's there...
3/4 fine thread 4"
How do u remove the drivin clutch bro
Got it off.used a pry bar it came off easy
What is the special tool called
Clutch puller
Awesome video but you skipped over HOW to remove the chain.
That's where I m stuck
Take the bolt off the transmission sprocket and slide it off.
Take the bolt off the transmission sprocket and slide it off.
Take the bolt off the transmission sprocket and slide it off.
Take the bolt off the transmission sprocket and slide it off.
Take the bolt off the transmission sprocket and slide it off.
Motocheez removed starter from the bottom, seems much less steps involved.
Sounds like a person that has just looked at one and never actually worked on one. Obviously I could be wrong. You damn near have to rip it into 100 pieces to check the damn air in the tire. 🙄
That rewind cover does that have oil inside of it?
It should not. If yours has oil, the crankshaft seal behind the flywheel is probably leaking. Get that fixed asap to avoid running the unit lean burning up the piston!
I have a lot of water in the crank Balance gears is that the head gasket or the water pump gasket
Water pump seal most likely.
Seals and gasket
Excuse me...."Brap"....not Brad.
im no mechanic and learned you dont NEED a special tool to remove the drive clutch, just jump start her, rev. her a bit and watch that thing go flying!
Polaris way overcomplicates things. Most other older machines are 3 times as easy to work on
Yeah a starter on the bottom closest to mud and water is just a poor design too. I’ve seen dozens rusted stuck.
@@BrapStuffyou can go ahead and add mine to your count.