Starter Rebuild - Snowmobile Forum: Your #1 Snowmobile Forum

rgoers · 08-27-2005, 10:12 AM

Anyone ever rebuild a starter? Mine quit working (2000 ZL550) last winter. Thought it was a battery, but tried bypassing the solenoid with a jumper, and no-workie.

Seems to be free-turning, so I assume it's just brushes.

Any tips (besides "take it to a professional")?

sesnopro · 08-27-2005, 01:00 PM

starter are not hard to take apart, there will be about 6 pices to the whole thing.

**smallengineguy** · 08-27-2005, 07:56 PM

Welcome back! You'll need to replace the bottom end "stuff" (brushes, springs, bearing). They usually make a kit for it.

rgoers · 08-27-2005, 11:06 PM

Quote:

Originally posted by smallengineguy
Welcome back! You'll need to replace the bottom end "stuff" (brushes, springs, bearing). They usually make a kit for it.

Thanks SEG. It's been a busy summer!!! Kids have worn me ragged. Can't wait for the snow, so I can go out and relax.

I saw an Arctic Cat kit on eBay for $26. Sound about right?

BTW - I might be able to catch up on repairs if I didn't have to spend the PM in the emergency room.

I was running some CAT5 wire downstairs, and stood up too quickly underneath my furnace chimney pipe. Put a 2 inch gash in my head. Got 4 stitches out of the deal, and a few hour setback on my project...

**smallengineguy** · 08-28-2005, 06:42 AM

Now you're all set. Every project I work on, I get a cut somewhere. But I've determined once I get one, that's it for getting wounded on that project. So you shouldn't get any more wounds on the CAT5 thing.....$26 sounds about right for the kit.

rgoers · 08-28-2005, 01:42 PM

Great... $26.

I did finish the project when I got home. Didn't get hurt again either. I think there's something to your theory.

rgoers · 09-05-2005, 10:53 PM

Got the starter pulled apart. Brushes were shot - some brush wires were broken.

The only thing I'm concerned about is the front shaft looks worn pretty bad. I would have to replace the whole armature assembly. Browns lists it for $152 (CAN). Ouch!

I'm thinking that since the starter doesn't run much, maybe I can get away with the worn shaft?

**smallengineguy** · 09-06-2005, 07:24 AM

It shouldn't matter too much, just get a good lube to put on that shaft. If you were going to use it a lot, I'd say replace it.

rgoers · 09-06-2005, 06:55 PM

Sounds good to me...