How to get C clip on starter 410207700

[greginmadtown]

Ok, So I rebuilt my starter for my 1996 GTI 717. I did not take off the c-clip on the end of the shaft. But when I put it back on the ski and tried it, the starter was not throwing out the starter clutch. So removed it cleanup the shaft, put some dry lube on it, cut off the old c clip. But, Damn!!! I cannot get the new c clip back on. I tried using a socket method I saw on youtube but that just bent the new clip, so I am ordering some new clips (Part 410207700 ). Anyone have suggestions?

 

[mikidymac]

Not really it’s a royal pain. I notched a steel plate to push it on. A socket can actually compress the clip making it even tougher.

 

[greginmadtown]

Hmm, I'm having trouble visualizing what you made to help. Can you describe it or take a pic please?

 

[PorknBeans]

I just finished rebuilding my OEM starter for my '96 GTi as well. And it is a royal PIA to remove that thick metal C-clip!

To install the c-clip, I attached a large adjustable vise grip or oil filter plier(this plier has the curved jaws) to the starter's mounting flange to hold down the metal collar and to keep the spring compressed in order to keep the notch in the shaft exposed. Simply squeeze on the c-clip to the shaft's notch and remove the pliers.

I replaced the starter clutch w/bendix gear(mine was barely extending also), new brushes, o-ring seals and positive(+) post, spring, collar and insulators in a kit from OSDparts.com. I compared the OEM brushes to the new brushes. And they were worn down about 40% after being in service for 23 yrs. Not bad for never being changed out and having a lot of hard use on this ski from family use.

http://osdparts.com/index.php?main_page=product_info&cPath=595_602_6&products_id=15098

 

[greginmadtown]

I ended up going to a small engine repair shop they help me put on the c clip. but it turns out I did not put in the new brush correctly because I did not worry it to hate the notch and the magnetic housing with the new brush assembly correctly so the starter was running backwards. and I understand electric motors and have learned to read that the Sea-Doo manual much closer!