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Discussion Starter #1
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
 

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Discussion Starter #3
I have went to a few rebuild shops here in Kyiv. They problem is the magnets are super thin, like between 1/8 and 3/16" and are curved to fit the shape of the starter.

So you need magnets that are the same thinness and also curved the same as the shape of the housing they glue to. They all told me if I can find the magnets they can glue them in no problem and glue them much better than from factory.

From factory there was 3 drops of glue applied to each magnet.

I am not sure but I think that the magnets from the xv1600 are the same. I havent taken the starter apart to look at it and verify yet though. I got a super deal from a guy here on the forum on a used warrior starter. I will have it sent over here to Kyiv and once it gets here I will do a side by side with the Warrior starter and the XV1600 starter. Just to show the differences.

But at this point unless someone has a bad starter laying around I can steal the magnets from I have looked and looked but dont know where to get the magnets. It appears the starter was produced by Yamaha and if you look at a parts schematic you can buy just about everything but the magnets and the housing they glue to.
 

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hey monty ...neat post .... i'm pleased your back on the road again

you are certainly the man to show the differences

i saw you say the 1600 is slightly under powered but works ...that goes with pascal saying its 100 watts light compared to the warrior starter

and as for 600 dollar / euro / sterling warrior starter having the magnets fall off well!!

yamaha do let them selves down sometimes ...nearly all the chrome billet parts i spent a fortune on ...rusted thru in 1 to 2 years ...the worst by far was the ball finished top belt cover ..the chrome has literally fallen off !!

compared to the now rare mapan sissy and rack ...10 years before even the smallest scare appeared


when are you heading back to kyiv?
 

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well.. i'm in the same boat now.. starter has come undone.. if anyone has a lead on a working starter.. plz lemme know
 
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