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You guys probably all know how they work, but in my electric starter on my 96 EXT deluxe, the "rod" that spins and comes out to spin the gear doesn't come far enough. It just spins, but can't seem to make it all the way out. What's up?


P.S. Look outside... its snowing!!!
 

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Check to see if the bolts on the mount are all tight.  I have had two starter brakets that had loose or broken bolts because of the vibration of the engine.  Have had to get one bolt welded and one re-tapped, others were just loose.
The newer Cats are getting away from the starter mount on the engine because of these problems.  Now the starter is mounted on the right side of the frame and a flexible shaft extends over to the starting gear where it engages with the fly wheel.
 

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Check with your local dealer.  I just had this problem on my sled, exact same thing.  They fixed it without charging me for any parts.  Of course, they were charging me for the new clutch, ring gear, belt, and associated hardware I needed.  Starter works like a charm now.  Could be just corroded contacts on the solenoid.
 
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