[keandobus]

I have a question for anyone who serviced ATV's specifically the side where the pull starter (on older models) and/or the starter system in general (all models).

I have a 2006 Polaris 450 and I go through a starter about once a year. I was told by the local dealer that starters should have a life of at least 3 years when all is good with seals, etc. Basically moisture or water gets in the starter itself or condenses somehow and the needle bearings seize up on the output shaft to the point that I get a solenoid click. Alternately it could be constantly turning when running via the flywheel with no engagement (see next paragraph for description of issue).

The person I bought it from says this has been a common problem for them, hence I got it with that problem along with a broken recoil which I rebuilt and starter was replaced. I always seat the pull handle properly before a run or when storing.

I recently had the starter freeze up on me again and it seems moisture got in the starter somehow even though I do not go through mud or water at all, mostly dry trail riding. No dust getting in the case, just water. I can only assume rain is the issue as I do not have a dry storage place. It is frustrating but that issue is for another thread. Upon inspection, most or all the grease was gone after a year. Maybe more grease next time...

What I am asking is should I regularly grease the Bendix shafts (both sides) and also should I grease all the teeth there is (starter, Bendix drive, flywheel) and how often and how much? What grease should I use, waterproof or my main Lucas Xtra Heavy Duty (green kind)? It is safe to use as a dielectric, and works well for me on practically everything. But Polaris makes a special grease for this side as I found by searching grease. Always something special from them lol. Should that be used or does it matter? Service manual seems vague on this issue of lubing the starter side...

 

[Diesel man 03]

I have never heard of greasing the starter drive or bendix yearly, on my 400 the problem was moisture making the brushes hang up, this was not a yearly thing but the solution for me was to remove the starter,clean up the brushes in there holder, spray with wd40 and put it back on.

 

[keandobus]

Thanks, I know on outboards and other type of drives including your basic automobile that greasing up the flywheel is not important and rather messy if overdone, due to centrifugal force flinging it off eventually. But the starter issue I am hoping doesn't reoccur next year. It seems like water got in past the water seals and froze the output shaft's needle bearings up like the last one, so I am thinking about taking apart the starter next year (or maybe before I put it away for the winter) and using some waterproof grease on the needle bearing end. The dealer said to use dielectric or another electrically compatible lubricant on the brushes, so I will heed that and your advice when I tear it apart. Just seems to me they should last longer without having to do this, but they are ATV's I guess. Maybe I had a dud as this new one sounds much more like a popo startup then the last one I was using. Anyone else who has this problem and any better solutions, let me know. I will post when I take it out again to do the checkup.

 

[cxcmoto]

Going through a starter every year is definitely not normal unless you are just using it all of the time. I am not aware of anyone else that is lubing the starter ? Are you washing the ATV with a power washer and getting water into the starter that way? Condensation? Is there water inside the recoil housing? Is the plug installed in the bottom and top of the recoil housing?

 

[keandobus]

Thanks for the reply, I just put in the proper gasket that came with a recoil rebuild kit, so hoping that helps, previously I had used RTV black sealant and bought some High Heat Copper to use if needed. As far as power washer, no I was told that causes water to get into sealed bearings such as wheel bearings and other places. I rarely clean it as I dont get it real muddy, sometimes dusty but avoid mud as much as possible (even though it can be fun). Both drain/inspection plugs are replaced and in good, and never had to drain any major water out. I had noticed some moisture in the housing before on the recoil rope and the nylon wrap around the wires from the stator before, never soaked but damp. But the rubber wire seal looks good yet, I have heard it can get in that way and cause issues. Also, I always seat the recoil rope handle around the case. Should I try and put some orange silicone around that stator wire part along with having the proper gasket installed?