Starter removal/engine removal????

[pqtiii]

My 1991 xp's starter locked up last summer. I just tried to see what was going on to get it ready for summer. I charged the battery and tried to start it again. Just a small click. Voltage was fine then tried to turn the engine over by hand. It was locked up until I put a pipe wrench on the flywheel/shaft. It made a noise then rotated fine. The starter seemed to be engaged and locking the engine up.

My problem is I could get the bottom bolt off the starter, so I went crazy and started removing the engine. It is all ready to come out except the engine is still attached to the prop shaft. Is there a realistic way of getting the lower bolt out or should I just pull the engine out? If I need to pull the engine, what is the procedure in disconnecting the prop shaft from the engine? This has been a HUGE pain.

Thanks
pt

 

[LouDoo]

I would do everything I could not to have to remove the engine. I have changed a starter without pulling the engine, it's tough but in can be done. You just need to find the right combination of extensions, universals to accomplish the job. Also the right amount of cus words.

The problem with pulling the engine is you have to pull the pump to remove the drive shaft, and to reinstall the engine you need to beg, borrow or rent an alignment tool to reinstall. If you don't realign the engine you will, unless you're lucky, have vibrations.

Lou

 

[pqtiii]

I'm open to any suggestions!!!

 

[LouDoo]

Have you tried to remove the exhaust mainfold?

 

[pqtiii]

The exhaust is off, the engine mounts are unbolted. I got the top bolt out, but can't get to the bottom one that is between mount bracket and starter. Not even sure what type of bolt it is. I used an extension and still can't tell what the type of bolt is there.

 

[lilraz]

i removed the exhaust and used a deep socket and three extensions and had no problem. there might b a third one that is attached to the back of the starter that mounts to the motor on the side. it should b a 1/2" socket.

 

[pqtiii]

I might have to try the socket deal. The upper bolt was actually one with the allen wrench insert.

 

[Kozerxp]

Did u try to restart it after u got the motor free it sounds like the motor was locked up and the starter could not spin the motor over I think ur motor was the prob not the starter

 

[pqtiii]

I tried jumping the starter relay and it still clicked a little. I could turn the engine over by hand and it was making compression.

 

[pqtiii]

Finally got it off. I had to use a camera to figure out what bolt was on there. It turned out to be another allen head bolt. The return spring was bad and there was a lot of rust. Should I rebuild it or get another one? Where is a good place to get a reasonable priced starter?