REMOVAL:

Starter removal is a fairly simple procedure. The trickiest part, is getting the pipe out of the ski.. This sometimes takes patience, and trial and error. While you have the starter out, I would recommend checking for broken motor mounts. Any broken mounts can easily be replaced while the exhaust is out.

Tools needed:

13 mm socket, ratchet, and extensions

10 mm wrench

Flat screwdriver

Razor blade

1. Remove the positive cable from the battery, to prevent any electrical shorts.
2. Remove black water hoses from the front of the pipe. Loosen the large clamp that attaches the pipe to the water box. Remove any small, clear hoses that attach to the pipe (mark location, if necessary).
3. Using 13 mm ratchet or wrench, remove 1 long bolt that holds pipe to the engine (located between the pipe and the side of the ski). Next, remove 4 nuts (or bolts) that attach pipe to exhaust manifold. Remove pipe from ski.
4. At this point, you need to remove the positive cable to the stud located on the top of the starter (10 mm nut).
5. Remove any cooling water hoses where they connect to the block, if necessary.
6. Locate 3 starter mounting bolts (2 long on mounting flange, 1 short passing through steel bracket), and remove, using 13 mm ratchet and appropriate extensions.
7. Remove starter.

REPLACEMENT:

Starter replacement is basically the opposite procedure of starter removal. While you have the starter out, I would recommend checking for broken motor mounts. Any broken mounts can easily be replaced while the exhaust is out.

Tools needed:

13 mm socket, ratchet, and long extension (12″ if possible)

Razor blade

Loctite 271 (red)

Torque wrench

Parts needed:

Starter gasket, or o-ring, depending on the model (see your dealer for this part)

Small cable ties

1. Locate mating surfaces for starter to engine. The starter is sealed with a replaceable seal. Remove any old gasket material or silicone from the surface located on the engine, using a razor blade. Check the sealing surface on the starter and clean if necessary.
2. Peel the backing off the gasket and apply the seal to the surface on the engine, making sure it fits evenly surround the opening. Some gaskets don’t have adhesive backing, but you can use a little silicone sealant, if you prefer.
3. Apply Loctite 271 to the threads of the 3 starter mounting bolts, and insert starter into engine, aligning 2 mounting holes. Insert 1 long starter bolt into the bottom hole, and 1 long one through the ground cable (if necessary) , and into the top hole, torquing to 22 N m (16 lb ft). Next, insert 1 short starter bolt through steel bracket and thread into engine, torquing to 22 N m (16 lb ft).
4. At this point, you need to reattach the positive cable to the stud located on the top of the starter (10 mm nut).
5. Replace any cooling water hoses where they connect to the block, if necessary.
6. Install new exhaust gasket, and reinstall pipe, torquing bolts to 25 N m (18 lb ft).
7. Reconnect any hoses that were removed earlier, and reattach battery lead.
8. Attach water source to flush fitting and start ski in your usual manner. Check to insure that there are no unusual sounds coming from the driveline. Also check the cooling and exhaust system for any leaks. If everything checks out, test the ski on open water.

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