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  1. #1
    Kory70's Avatar
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    Stuck Starter Removal Need Help, Polaris Virage

    Dear Friends

    I have to remove the starter but its realy stuck. Polaris Virage 2 cyc 1 carb red engine
    The starter wont come I have heated and also hammered. I did not want to remove the engine and open the flywheel cover
    If you have tips and advices it will be helpfull

  2. #2
    Click avatar for tech links/info K447's Avatar
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    Why not remove the engine from the hull and open flywheel cover?

  3. #3
    Kory70's Avatar
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    Dear Keith
    My finger is badly hurt while removing manifold also I do not have an allining tool for engine and lonelly at this time
    And my bendix works fine.


  4. #4
    casey67's Avatar
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    There are 2 rubber o-rings on the end of the starter. I am guessing they are stuck, prying and twisting is all you can do.

  5. #5
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    I'm speculating it has seen salt water. It is likely corroded tight. In the long run, it'll be simpler to remove the engine. You have the worst of it already done, the exhaust. You shouldn't have to re-align the engine to the pump...though it would be a great opportunity to check it.

    I've adopted the practice of coating the starter nose piece, including the O-rings, with anti-seize whenever it is convenient to do so, to prevent the situation you find yourself in.

  6. #6
    Myself's Avatar
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    Penetrating oil around where the starter goes into the engine and wait a couple hours then repeat. I have had good luck with flat blade screwdrivers. One top and one bottom and pry the starter backwards. If you can get a helper to use a ratchet extension and place on the starter and tap backwards while you pry it might just pop loose.

  7. #7
    Kory70's Avatar
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    Dear Friends thanks for your advices
    Today I remove the engine and cleaned every place , i got shocked when i see the
    bottom of the starter; all get rusted and the cover plate is like a paper

    I need your advices what to do step by step,
    what else to check at this time while engine has removed

  8. #8
    Kory70's Avatar
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  9. #9
    Kory70's Avatar
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    I opened the Flywheel cover

    I could not remove the flywheel I dont have a tool for flywheel remover

    Also I couldnt remove starter kicked many times with the hammer handle wood and the handle wood has cracked !!!

    Just moved only 1mm.(0,0393700787 inç) the starter
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  10. #10
    martincom's Avatar
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    It appears as if you had your wood hammer handle against the armature, so all your driving force is being transferred through the armature to the starter end plate. You've likely damaged the end plate and possibly the armature. I'd look for something to utilize as a pry between the outside of the nose piece housing and the outside of the flywheel housing. Continue to soak it down with penetrating oil and heat the flywheel housing around the starter nose piece. Also, work the nose piece back and forth, by driving the nose piece housing back into the flywheel housing. As a last resort, I'd look for a length of pipe or something that is cylindrical/hollow so you are driving against the starter nose piece housing, from inside of the flywheel housing. I'd be very hesitant to do the latter as the nose piece end could "mushroom", further complicating the removal.

    It appears to have been submerged fro a prolonged period. I can't telll from the photos, but if there is a lot of rust/corrosion debris, this will be drawn to the flywheel magnets and collect. The clearance between the magnets and the stator lamination is close. This debris could damage the magnets. I'd recommend obtaining a puller and removing the flywheel for further cleaning/inspection. This is the flywheel puller I purchased/utilized based upon HiPeRcO's recommendation.

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