96 waveraider starter - PWC Forum: The best hang-out for Personal WaterCraft enthusiasts
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Old 04-29-2010, 07:21 PM   #1 (permalink)
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Default 96 waveraider starter

I was given a 96 Yamaha Waveraider 1100- Clicks in the electronic box at the front of the motor but won't start. Where is the starter located in case I have to take it off to have it checked. I have a Yamaha repair manual but it only shows the starter off the motor.
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Old 04-30-2010, 06:42 PM   #2 (permalink)
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It's located under the exhaust manifold all the way down at the bottom. Just above the motor mount. It's a really tough location. Once you have the top part of the exhaust water pipe system removed check the bolts on the exhaust manifold itself ... 12 bolts total. If they're slightly rusted you may want to leave it in place and work the starter out from above. If you break bolts in the block you'll have to pull the motor. It's damned difficult, but you can remove the starter blind. I just knocked mine out. I have a '98 XL1200. But before you get started on this project, take a test meter and set it up for 12 volts. Take the positive and attach it to the positive lug on the starter. Then clip your test meter negative to the neg side of the battery. Press the start button and see if you get 12 Volts at the starter. If you do, the solenoid is working and the starter is shot. Good luck.
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Old 05-30-2010, 05:25 PM   #3 (permalink)
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Default replaced starter

I removed the starter and took the cover off. The brushes were rusted to the armature. I replaced the starter and the starter relay, but now it spins but doesn't engage the motor. Am I missing teeth on the flywheel or is there another part it could be.
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Old 06-01-2010, 06:16 PM   #4 (permalink)
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You may need a new starter Bendix. It's located under the flywheel cover. Not an easy job, but you're going to have to check inside it to see what's happening. It may be frozen in there due to sitting and probably the lack of lubrication. I'm not a jetski mechanic so I can't tell you anymore about it. Somewhere on this site they should have a link to a website that deals with the procedure. I checked my Clymer Manual and you have to disconnect the battery, plug wires and electrics and then take off the flywheel cover and I think you have to pull the flywheel to pull the starter Bendix out. I would check the Bendix in place to see if it frees up before pulling the flywheel. If you're missing flywheel teeth at the Bendix pinion, then you have no choice. Sorry for the bad news. Hope somebody else weighs in here for you. Good luck.
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Old 06-03-2010, 07:11 PM   #5 (permalink)
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Default new starter doesn't work

Thanks for the reply, and I think you are right,

I called the starter manufacturer and they thought their starter was bad so they sent me a new one. Same exact situation, spins and doesn't engage. I pulled the PTO cover off, removed the plugs and turned the motor, but it still won't engage so I am going to pull the front engine cover to see what the bendix looks like or if it is stuck. If it is just stuck, can it be knocked lose and then lubricated or does it have to be replaced if that is the only issue. My diagram shows the flywheel has a stator inside it and the flywheel bolts to another part (not labeled) that appears to connect to the starter shaft and it is held on by a key. Hopefully I can find detailed instructions on how to do this.
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Old 06-04-2010, 09:04 AM   #6 (permalink)
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Look on ebay for a starter bendix for your type of stater to see what it looks like and you'll have some insight on how it is engaged with the flywheel. I've never replaced one, but according to the manual you have to pull the flywheel to remove it. That's why I said maybe if it frees up with lube you can avoid pulling it. If it's rusted up you'll have no choice but go the full procedure to remove it. When you pull the cover make sure you catch any shims that may fall out, because the bendix tip fits into the front cover with shims between the bendix and the cover. This site should have something in that deals with the starter bendix removal. Having said that though, I'm looking for carb information for the shaft seals and check valve checking but there isn't really a whole lot for reference.
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Old 06-04-2010, 03:50 PM   #7 (permalink)
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Default starter bendix

pulled the front cover and the bendix or idler/pinion gear as my manual calls it would just flop around when I pulled it out engage the teeth with the flywheel, so something on the inside has to be broken or the teeth are worn off. I am going to try and pull the flywheel, but I don't have a detailed manual. Does yours mention anything about the flywheel having to go on with a specific alignment. I am going to try and mark it, but just wanted to know.

Do you have an online manual link -mine is just a very high level reference manual and not a real service manual.

Thanks for your replies on this.
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Old 06-08-2010, 06:36 PM   #8 (permalink)
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I have a Clymer manual '93-'96. Haven't found anything on line yet. Sorry for the delay getting back.

There is a woodruff key on the crank to align the flywheel. You need to secure the teeth of the flywheel gear before attaching the puller. Remove the center bolt. Book says the tools to secure the gear from turning and the puller are Yamaha tools, but I guess any puller will do. Locking up the teeth on the flywheel might be a problem. When you set up the puller and put it under load, you may have to hit the center bolt of the puller while it's under load. Do not hit the flywheel. When it pops loose, you can remove the idler gear/bendix. While the flywheel is off, inspect for metal particles or flash that might have accumulated on the magnets and remove anything. The bendix may have self-destructed in there.

I would have Yamaha inspect the flywheel for cracks, teeth and electrics, because the stator and pulser are inside the flywheel.

When you reinstall the flywheel, replace the woodruff key, wipe idler gear/bendix w/grease, position flywheel with the key slot, oil the bolt and washer and tighten to 51 ft/lbs torque.
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