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Followup - started right up! Some notes...
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Posted by Shauno [Email] (more from Shauno) on Sun, 5 Jan 2014 18:36:43 Share Post by Email
In Reply to: No start question - starter?, shauno, Wed, 1 Jan 2014 13:29:03
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OK, starter replacement was much more challenging that I expected, after reading numerous posts here on the procedure. Here are my quick notes - not instructions per se, but some pointers that might help out the next victim :) All told it was about 3 hours.

1) I did not remove the clutch cover (I'm a manual turbo) but rather used a large screwdriver to bend the plastic back just enough to allow open-end wrench access to each of the two nuts holding the starter assembly on (one at a time). Note: you can't just unbolt the starter from the clutch - the bolts will spin. You need a wrench on either end. I didn't realize this and was puzzled for about 30 minutes. It has been nearly 20 years since I did a clutch job on a 900 so I haven't seen the inside of the plastic cover in some time.

2) The outboard bolt didn't allow for a socket to fit over it. But again, you aren't turning it - just hold it still and unbolt from the clutch cover side.

3) The back of the starter assembly has a bracket holding it to the block. Those are hard to get to, but an extension and some patience will allow you to unbolt it. I didn't remove the bracket from the starter (2 8mm nuts I think) until it was out.

4) I removed the tubular brace that goes from the clutch to the throttle body. It appeared to be held on in my case by a large square nut. That doesn't turn - you unbolt from the clutch cover side as you did with the starter assembly. It blocks removal of the starter and crosses right in front of the solenoid so definitely take it out.

What a feeling though to have it start right up on the first try after reassembly! Worth every achy muscle I'm going to have from bending over the car today.


posted by 108.202.10...

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