Popo starters

Went to change bearings (rear) on the rzr n do some welding n the !?$@ thing wouldn't start. This starter is only a year old. One of the magnets had broken cuz the bearing in the end cap had failed again. So I removed the bearing n put a copper bushing in instead, seems to work well. I had the left overs of 5 starters. I did some comparison, this is what I found, first the bearing goes out which causes second: the armature to get a little off balance which in return breaks magnet or causes glue holding magnet to come loose then binds up or breaks. The oem Polaris starter has a metal tube that seperates armature from magnets, that is the only difference between Polaris n aftermarket starters. I don't waste the money on popo starters anymore, I just replace starter about once a year. If it fails on the trail I can pull it out, break it down n use it to start the rzr in about 15 to 20 minutes then replace when I get back to camp. The point is starters r junk, Polaris, super atv etc. buy the cheapest u can find n keep several on hand.

Carry a spare in my rzr. Wish I knew how to work on them like that.

They r pretty simple, trust me if can work on them I'm sure u can!

Thanks for the info..

I have the same kinda trouble lately... I have 3 tore down in pieces........

Dave where did you get the copper bushing? And how the hell did ya get the bearing out??????

Talked to a guy yesterday and said he gets his starters from EMS in WV........

I just get them from JBS. Those lasted a while and were a good starter when I had my 800

It was something just laying in my nuts n bolts box. I don't know where it came from, I cut it down n honed it a little. It fit perfect so I'm gonna run this starter a while n see how it does. If it lasts I'll change the new starter I have the same way. I used a press to get the old one out. It was a pain, it came out in several pieces. Next time I think I will use a step drill bit but I will have to modify the bit to work. I think it will do the job. I'll try to figure out where I got the copper bushing n let u know. The bearing just can't handle the sudden torque.

Mine came from JBS as well, the starters r not built to last, none of them!

Super Dave wrote:

It was something just laying in my nuts n bolts box. I don't know where it came from, I cut it down n honed it a little. It fit perfect so I'm gonna run this starter a while n see how it does. If it lasts I'll change the new starter I have the same way. I used a press to get the old one out. It was a pain, it came out in several pieces. Next time I think I will use a step drill bit but I will have to modify the bit to work. I think it will do the job. I'll try to figure out where I got the copper bushing n let u know. The bearing just can't handle the sudden torque.

Do you think it's the high powered batteries you folks are running....

Well I did try to help it and took caulking around the caps trying to help seal out water and it helped get some more life out of it

What kind of life are you guys getting out of your starters? I see Super Dave says about a year, but what about the rest of you? Is this riding 2-3 times a month, or what is an average? I'm trying to start getting a list of common things to be prepared for and to budget expenses.

Mine lasted right at 1200 miles before it went out. It was a couple years old. If you ride more than the time will be shorter I'm sure. All depends on how much u ride.

CntryFun wrote:

What kind of life are you guys getting out of your starters? I see Super Dave says about a year, but what about the rest of you? Is this riding 2-3 times a month, or what is an average? I'm trying to start getting a list of common things to be prepared for and to budget expenses.

My PO PO starter lasted about 4 years..... The after market ones I am on #3.

Super Dave wrote:

It was something just laying in my nuts n bolts box. I don't know where it came from, I cut it down n honed it a little. It fit perfect so I'm gonna run this starter a while n see how it does. If it lasts I'll change the new starter I have the same way. I used a press to get the old one out. It was a pain, it came out in several pieces. Next time I think I will use a step drill bit but I will have to modify the bit to work. I think it will do the job. I'll try to figure out where I got the copper bushing n let u know. The bearing just can't handle the sudden torque.

A friend of mine said he was gonna machine one from some kinda self-lubricating brass or something........

CntryFun wrote:

What kind of life are you guys getting out of your starters? I see Super Dave says about a year, but what about the rest of you? Is this riding 2-3 times a month, or what is an average? I'm trying to start getting a list of common things to be prepared for and to budget expenses.

Mine is a 09 rzr with 4300 miles on it and my starter is the original and I have the stock battery. I do not have a sound system....I'm thinking these high powered batteries are killing the starters..

I had a stock battery.

TBONE21 wrote:

I had a stock battery.

Tbone...your starter rusted from the inside out due to not being able to ride that much...you need to start riding more..

Sometimes I wonder if washing around the starter lets water get to the bushing causing it to rust. Just a thought because my rzr had 3500 miles on it and was 2 yrs old with no problems. Another thing is how many times you start it. When I ride alone, I don't shut the engine down but maybe 2-3 times all day vs 6 or more times with a group. Also, I never had it in mud holes deep enough to get to the starter other than going through a short one real quick and staying moving. I think there is alot of stuff that has an effect on the life of them.

Hump wrote:

Sometimes I wonder if washing around the starter lets water get to the bushing causing it to rust. Just a thought because my rzr had 3500 miles on it and was 2 yrs old with no problems. Another thing is how many times you start it. When I ride alone, I don't shut the engine down but maybe 2-3 times all day vs 6 or more times with a group. Also, I never had it in mud holes deep enough to get to the starter other than going through a short one real quick and staying moving. I think there is alot of stuff that has an effect on the life of them.

I agree, my 08 that I sold a friend of mine has around 5k miles on it now. Still the same stock starter. He runs a big stereo too. Now he has had a few batteries put in it . But the machine was never in deep mud or water.

My 2010 has a little over 2k on it with the same starter too.