Starter Gear '04 upgrade
I'm having the same problem on my '03 400. Bob Piper at North Tahoe Motorsports confirmed the same problem on my bike and said it needs the starter gear upgrade that the '04 bikes got which is essentially a series of gears that act like a worm gear so when it does back fire the gears gradually work themselves back to absorb the impact as opposed to the single gear which takes all the impact w/o any give either damaging the gears leaving a tooth in the motor or damaging the starter clutch which I just replaced and costs $386.00. Here's the parts list for the upgrade to the 'or starter gears.
MFS450526510 gear $64.06
MFS45042651012 gear $145.74 not sure if that last 1 is a 1 or a / double check.
MFS450526521 gear $47.41
MFS450526522 gear $76.06
MFS450526523 clip $5.37
(2) MFS450426524 washers $4.88pr.
So, you can keep forking out $386 to fix the problem or spend the additional $344 plus labor and solve the problem.
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