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Discussion Starter #1
So, after my top end rebuild, it started and ran fine then I noticed the stator cover gasket leaking. I removed the cover replaced the gasket and now it wont' start. Starter clicks once when turning the key and dash lights go out if key is held on. Battery is fully charged. Anything it might be before I take the stator cover off again?
 

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Discussion Starter #4 (Edited)
I removed the stator cover and couldn't find anything odd. Removed the starter to flywheel gear and turned the key. The starter spun normally. Put it back together. Now wait 24 hrs for form a gasket to cure. Then I'll try again.
 

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Discussion Starter #6
Update...not the solenoid. Replaced it and same thing...one click(starter) and ground wire jumps when it clicks. Reading back to 2014 there was an issue with a bolt(stud) coming loose next to the flywheel. Would this be my next move or look into starter?
 

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Did you torque the stator cover to spec? I also recommend using the OEM gasket. A friend of mine had an issue with the starting turnin very slowly after he took off the cover to fix an oil leak and tightened it down too much, and used silicone gasket maker.

the starter shaft seats firmly into a bushing on the stator cover, if you put the starter shaft in too much of a bind, it doesn't allow the starter motor to spin freely and can overload the solenoid.

Don't know if you've fixed it or not yet, and I don't know that that's your problem, just thought I'd share, there is also a numbered sequence to torque the bolts down.
 

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Discussion Starter #8
Did you torque the stator cover to spec? I also recommend using the OEM gasket. A friend of mine had an issue with the starting turnin very slowly after he took off the cover to fix an oil leak and tightened it down too much, and used silicone gasket maker.

the starter shaft seats firmly into a bushing on the stator cover, if you put the starter shaft in too much of a bind, it doesn't allow the starter motor to spin freely and can overload the solenoid.

Don't know if you've fixed it or not yet, and I don't know that that's your problem, just thought I'd share, there is also a numbered sequence to torque the bolts down.
This could be my problem...I used permatex fipg instead of factory gasket. Will remove and replace one more time...thanks..I'll let you know.
 

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Discussion Starter #9
Did you torque the stator cover to spec? I also recommend using the OEM gasket. A friend of mine had an issue with the starting turnin very slowly after he took off the cover to fix an oil leak and tightened it down too much, and used silicone gasket maker.

the starter shaft seats firmly into a bushing on the stator cover, if you put the starter shaft in too much of a bind, it doesn't allow the starter motor to spin freely and can overload the solenoid.

Don't know if you've fixed it or not yet, and I don't know that that's your problem, just thought I'd share, there is also a numbered sequence to torque the bolts down.
RWB713...without your help I would still be scratching my head. I can't believe a gasket that's about 1/32nd inch thick could make the starter lock up but it did! Installed factory gasket and starter spun like it should. Thank you! This info should be in or have a sticky by itself. Sometimes our brains try to think too much into a situation. When I go back to the beginning of this problem (stator cover oil drip), the only thing I did different was use fipg instead of the factory gasket.
 

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Love this forum! good job guys. Never reuse the stator gasket on an early XP900. This will happen almost every time. Also, there is a washer on the outside of the circlip on intermediate starter gear post that is missing sometimes and will do the same thing.

Nate
Alba Racing
 

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Glad to help! And glad you got it fixed. I know firsthand what it's like to have a rzr as a garage decoration and it's not very fun at all!

It is amazing that a gasket can make that much difference, just shows how tight & influential design tolerances can be.
 

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Did you torque the stator cover to spec? I also recommend using the OEM gasket. A friend of mine had an issue with the starting turnin very slowly after he took off the cover to fix an oil leak and tightened it down too much, and used silicone gasket maker.

the starter shaft seats firmly into a bushing on the stator cover, if you put the starter shaft in too much of a bind, it doesn't allow the starter motor to spin freely and can overload the solenoid.

Don't know if you've fixed it or not yet, and I don't know that that's your problem, just thought I'd share, there is also a numbered sequence to torque the bolts down.
seen this before bet thats it
 

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Mine started fine before removing the cover. Now the solenoid just clicks.. it won't spin the starter. Battery has 12.7 v.
You need to get an OEM gasket and torque it to spec in the correct sequence, I sh*t you not, that little gasket is your problem. Get the OEM gasket, clean all the rtv off, re-install and torque to spec (89 +/- 9 in-lbs if my memory serves me correctly), and the is also a numbered sequence to torque the bolts in, When i get home i can send you a pic out of the manual
 

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One more thing if you don't mind. After putting in 3.5 qts. Of oil. It seems to still be all up top in the sump. Is this normal? I haven't had the machine long so it's new to me. I would've thought gravity would factor in here.. thanks
 

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One more thing if you don't mind. After putting in 3.5 qts. Of oil. It seems to still be all up top in the sump. Is this normal? I haven't had the machine long so it's new to me. I would've thought gravity would factor in here.. thanks
It's good, run it for a couple minutes, let it set for 30 seconds, then check the dipstick (don't thread the dipstick in to check oil level)
 

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Hi,
Don't want to hijack the thread but the cover on my XP has instructions to fully screw in the dipstick when checking oil level but the dipstick itself says not too so which is it? Mine is a 2012
 

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I’ve always not screwed it in because it’s on the dipstick.... my cover doesn’t say anything on it, ( stickers were removed when I got that machine if that’s where you’re seeing it )

Oil level will obviously read higher if you screw it in, go with what ya feel I guess lol, honestly I’m sure it’s finr either way
 

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