So quick write up on a starter install. Sorry I already had the old starter out so just reverse these steps for removal.
FYI My starter originally ate itself. 4 of the 5 magnets came unglued. Of the 4 that came unglued 2 of those almost completely disintegrated.
The first 3 photos are whats left of my starter. You can see how torn up 2 of the magnets were and how 1 is almost new just not glued in place anymore.
It was kind of an emergency situation and after some research I found that a starter out of an XV1600, 1999-06 part number 4WM-81890-01-00, should fit. Physically it looks very similar but it is, I believe, 800 Watts while the Warrior starter is 900 Watts.
The slightly less watts has led to a few times where the starter wouldn't turn the motor over. It seems to depend on where the motor stops in its cycle. If it happens to stop on a compression stroke the starter motor might have a hard time to crank it through that first compression. Once its past that it works.
Ok so now on to the actual install.
First the starter (4th pic) If you look at the starter on the left is the gears that engage to turn the motor. Just to the right of that gear is a black o-ring that seals to keep the engine oil in. If this o-ring is damaged get a new one. Then further to the right you can see the terminal where you hook the wire to.
Then the hole where it will slide into (5th pic) I got a little dab of engine and spread it around on the O-ring. This helps it slide in place easier with out tearing.
Then gently slide the starter into its hole while lightly wiggling it around and pushing to get the gears to mesh and seat the starter all the way.
Once that is done install the 2 bolts into the rear of the starter to hold it in place (6th pic).
Then re attach the wire to the terminal on the starter and then hook the battery back up and give it a try!
Its simple and easy
*Edit
Here is a video talking about starter issues and what a false start sounds like so you know there might be an issue with the magnets coming off in your starter
Someone was asking about the signs of a weak starter. So I was able to film what it sounds like along with talking about the starter and known issues with them. You want more dont forget to hit the subscribe button! https://www.youtube.com/watch?v=_bqvcXa74VI&feature=youtu.be
FYI My starter originally ate itself. 4 of the 5 magnets came unglued. Of the 4 that came unglued 2 of those almost completely disintegrated.
The first 3 photos are whats left of my starter. You can see how torn up 2 of the magnets were and how 1 is almost new just not glued in place anymore.
It was kind of an emergency situation and after some research I found that a starter out of an XV1600, 1999-06 part number 4WM-81890-01-00, should fit. Physically it looks very similar but it is, I believe, 800 Watts while the Warrior starter is 900 Watts.
The slightly less watts has led to a few times where the starter wouldn't turn the motor over. It seems to depend on where the motor stops in its cycle. If it happens to stop on a compression stroke the starter motor might have a hard time to crank it through that first compression. Once its past that it works.
Ok so now on to the actual install.
First the starter (4th pic) If you look at the starter on the left is the gears that engage to turn the motor. Just to the right of that gear is a black o-ring that seals to keep the engine oil in. If this o-ring is damaged get a new one. Then further to the right you can see the terminal where you hook the wire to.
Then the hole where it will slide into (5th pic) I got a little dab of engine and spread it around on the O-ring. This helps it slide in place easier with out tearing.
Then gently slide the starter into its hole while lightly wiggling it around and pushing to get the gears to mesh and seat the starter all the way.
Once that is done install the 2 bolts into the rear of the starter to hold it in place (6th pic).
Then re attach the wire to the terminal on the starter and then hook the battery back up and give it a try!
Its simple and easy
*Edit
Here is a video talking about starter issues and what a false start sounds like so you know there might be an issue with the magnets coming off in your starter
Someone was asking about the signs of a weak starter. So I was able to film what it sounds like along with talking about the starter and known issues with them. You want more dont forget to hit the subscribe button! https://www.youtube.com/watch?v=_bqvcXa74VI&feature=youtu.be