RESTO 95 XP800 Resto Thread

[Loganab13]

Sometimes there is a socket head bolt holding it on and few of us have something shallow enough to get in there. Go back with a regular hex head. Lots of times that bolt isn't even installed or the whole bracket is left off. Then you have the mystery bolt under the engine you have to feel for. Yep. Be sure you seal the starter with some RTV or something by the o-rings. Any moisture in there will cause the brushes to corrode and it won't work. Even OEM starters. I don't replace the bearings unless something is bad. 95% of the time I clean it all up and replace the brush holder alone. Chances are you get too large an o-ring for the bolt that connects to positive cable. I end up using the old one as it is smaller. Good Luck!

Yeah, I ended up having to use a stubby 3/8” ratchet with a low profile Allen socket. That thing was TIGHT and it was tough to get much leverage but I finally got it to break loose!

 

[Loganab13]

Had a rare day off today so I decided to take a look at the starter. Per the advice of @etemplet, I tore down the starter that came on the ski to try and figure out if it's an OEM or some sort of aftermarket. I'm still not 100% sure since the tag is painted over, but the internals seemed to pretty well match all of the other known OEM starters I've rebuilt in the past, with the exception of the exterior being painted black instead of white. To my surprise the internals were almost spotless and the brushes were in good shape. So I decided to roll the dice, clean everything thoroughly and put it back together. I bench tested it afterwords and sure enough, it appears to work like a charm.

I still haven't had the chance to send my MPEM off to @Minnetonka4me to get keys programmed to it and I didn't feel like swapping the gray box in from my 96 since it was getting late, so hopefully I'll have more time this coming weekend to check compression and see if it'll start. I noticed the rear e-box was broken at the battery tray, so I pulled it out and will replace it with a spare I had laying around. The fiberglass around the screws holding the box to the hull is stripped, so I'll have to address that as well. Rivnuts maybe?