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Went out in the Teryx on Saturday and after about 3 hours of starting and stopping the engine, I went to start the beast and the starter just spun but did not engauge. Thought the one way bearing was haning up, but when I pulled it down to see I found the Starter Gear that the one way bearing resides in had teeth missing in several locations. Has anyone out there heard of this being a problem on the teryx?? I have an 09 Sport with about 75 hours on it.
 

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Hi I'm George. I just had the same problem with the starter yesterday. the motor spins but does not engage. I believe I have the same problem with teeth missing on the starter gear. How did you go about pulling the starter motor?? I would like to try fixing it myself if possible. Can you order replacement parts on line?? I spoke with the folks at our local Kawasaki shop they are telling me over $600.00 to fix it. How did you solve the problem?? Hopefully I can get some help here. I have also been trying to find a maint manual for this rig.
 

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Hey George,
First off if you are not fairly mechanically inclinded I would pay the 600.00. The starter gear replace is cheap if done by you (new gear was around 60.00). Its the work that is a problem. The entire drivers side of the teyx has to be removed, parts of the frame, all plastic, battery, electrical components under the seat, etc. Do not try it without a manual. Once exposed and the exhaust system has been removed, you have to remove the whole side of the engine on the drivers side. It is not the starter gear that strips, but the crank shaft drive gear to the starter that is defective. Once the side of the engine case is removed the gear is easliy slipped off and a new one put in its place. From there is putting it all back together. I went slow and took my time and I completed the job in about 7-8 hours work spread over a couple of evenings. The parts are readily available online at kawasakipartsnation.com. I have subsequebtly sold my teryx because I was working on it more than I got to ride it. Never wilol own anotherone!!
dan
 
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