waverunner_guy

Is it possible to replace the red cable that goes from the solenoid to the positive terminal on the 2003 XL700 starter motor without pulling the exhaust assembly? At the starter motor terminal, the rubber boot is melted, the cable is badly corroded, and the nut feels like it also is badly corroded. If the exhaust assemby does have to be removed, are there any tips on how to do efficiently and without destroying too many gaskets, connectors, etc. Thanks to all those who dared to go deep inside the engine compartment and live to tell about it.

OttoRocket1868

Well i am in the process of tearing into my GP1200 i got this past summer, What a treat that was just to replace my starter and solenoid. Okay so, your kinda screwed in trying to replace that without pulling the exhaust unless your arms are nimble enough to get a socket under that exhaust and feel for the boot and nut on the starter motor. even if you got it off getting it back on would be a task in its self. now im not really familiar with how much room is in there since you got a 2 cylinder motor. SO, i would pull the exhaust its not too difficult, the gasket that is between the header and cylinders is a metal fiber gasket i believe from what mine looks like and it shouldnt rip if you just be careful removing it. thats honestly the only gasket you need to worry about. i would spray some PB blaster or any other penetrating lube on the header bolts on the top side they tend to stick because water sits on top of them over time. take your time and be patient!