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Starter Shaft wear.


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I have a 1993 King Quad LT-F4WDXP. I have had to replace the starter 3 times and each time the end of the shaft where the splines are cut in is all worn down. Getting ready to do it again any ideas on how to solve this problem? Is the a starter gear in the crankcase that is worn or broken. It make a grinding sound while cranking after a week or so.

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  • 3 weeks later...

First, here is my post about these:

http://www.quadcrazy.com/atvforum/suzuki-atv-forum/13672-91-98-king-quad-starters.html

Since, the machine I was changing these on has fully failed to start electrically. I talked to the local mechanic. He said the shaft the starter idle gear rides on breaks out of the recess it sits in. He has a fix for it at $500.

Pull the starter and look in the hole. Feel if the gear spins or wobbles. Otherwise you would have to pull the left hand crank case to investigate. I would first try to find a starter with good splines and see how that holds up.

For me, I just used to pull starting it. Not worth it for me to tear into it at this point. Winter project maybe.

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Yes pulled the cover with engine in the frame. All the bearings were good. The Pin shaft was stuck in the starter idler gear. Popped it out and it was bent thus making the gear run in an ovular rotation not a circular rotation.

Just went up and ordered a gear, pin shaft and spacer as well as all new gaskets. Think it will be whipped when we get it back together. Thx.

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