Starter Removal & Installation

Guide

Starter removal & installation

Difficulty: Intermediate Time: ~20 min Applies to: Gas boards Last updated: Sep 2026

Watch the walkthrough

Watch on YouTube ↗ · JETSURF Service Tutorials #8. Timestamps in the steps below follow the video's on-screen counter (0:03–1:24).

Pull the starter to replace it or to get at the engine frame behind it. The one detail that matters on the way back is the clearance between the starter and the freewheel — too tight and it binds, too loose and it won't engage.

Tools & supplies

5 mm Allen key (engine frame bolts)
3 mm Allen key (crankcase / starter screws)
Blue (medium-strength) Loctite

Removal

0:03 — Using a 5 mm Allen key, unscrew the four bolts securing the engine frame.
0:30 — Loosen the four screws on the engine crankcase with a 3 mm Allen key.
0:56 — Pull the starter, with its cable and connector, out.

Installation

0:56 — Apply blue Loctite to the starter screws.
1:04 — Set the starter onto the engine.
1:06 — Fasten it with the four screws using a 3 mm Allen key.
1:24 — Before final tightening, set a small clearance between the starter and the freewheel. Tighten the screws, then check the gap is still there.

Tip: hold the starter against its stop with light finger pressure while you snug the screws, then re-check the freewheel gap before torquing down — it's easy to lose the clearance as the screws pull the housing in.

Caution: don't skip the blue Loctite — the starter screws back out under engine vibration if fitted dry. Never run the engine with zero clearance to the freewheel.

Starter removal & installation