Recoil Slipped...
- Thread starter gmustangt
- Start date
Haha, been there, done that. The only way to get it back out is to take off the recoil housing and you will have to re-wind the recoil starter.
I just tie a knot in the rope by the recoil. Just make sure you run pull the rope out enough to run it up and out the handle hole before tying it. Also ( this is obvious ) make sure you tie a knot that can be undone after installing handle or you will have the dredded duh moment. Been there, it is kind of embarressing even if you are by yourself. The vise grip is also a good way to go, just make sure to only clamp it enough to hold and not so tight to pinch rope and damage cords.
Hate to be the bearer of bad news but the recoil housing is a major PITA to take off. I know it can be done with the motor in the chassis because I did it last year when my recoil rope broke.
I needed to "modify" my hex head allen socket by shortening the hex part, just to get the socket in there.... It is tight!
I needed to "modify" my hex head allen socket by shortening the hex part, just to get the socket in there.... It is tight!
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Ya you gotta take out the two mag side motor mount bolts and rock the motor up to get to the bottom allen head bolts. At least Polaris designed the chassis to get easy access to the mm bolts...
What size hex socket?
5mm. Just pull the motor mounts, it's way faster
When you get the recoil off do not take the nut off that holds the pulley down. The rewind spring will come flying out and it is a bear to reinstall. You should able to see the end of the rope through the hole by turning pulley clock wise. To get end of the rope started out the hole in recoil housing with a pick and needle nose pliers tie a knot in end when you get it out. It is possible that the spring unwound to far and will not have enough tension to rewind the rope. It is possible wind in more tension on the spring with the pulley mounted in housing but you will have to remove the rope first. This is how I do it. You will need a "C" clamp big enough to hold the pulley in place and a sharp knife.
1. Pull the rope out all the way install "C" clamp so that it traps pulley against housing do not over tighten or you could break pulley.
2. Use knife to remove black silicone that is covering knotted end of rope. 3. Untie rope and remove. 4. While holding pulley loosen "C" clamp so that you can turn pulley one turn clock wise line up holes reinstall "C" clamp then reinstall rope.
1. Pull the rope out all the way install "C" clamp so that it traps pulley against housing do not over tighten or you could break pulley.
2. Use knife to remove black silicone that is covering knotted end of rope. 3. Untie rope and remove. 4. While holding pulley loosen "C" clamp so that you can turn pulley one turn clock wise line up holes reinstall "C" clamp then reinstall rope.
After you have removed bolts you should be able to get a pry bar under the motor mount strap and lift it enough to remove the bottom recoil housing bolts. You do not need to remove the rubber mounts.
1
11RMK
Active member
Here is what I just got done doing..... My rope was melted by the turbo, not sure why but it did and then it wound up in the recoil housing.
Custom made tool to get to the bottom two bolts on the recoil housing.
I took a 3/8" drive 5mm allen socket purchased from Bomgaars, then I took a 38" x 1/4" adapter and put into the 5mm socket. I then took a 4" frinding wheel and ground the 1/4" adapter edges so it wasn't round anymore. I ground it so it had 4 flat sides and so a 7/16" wrench would fit over it.
You will need to carefully inseret the 5" socket with the 1/4" adapter into one of the two bolts that are hidden underneath. You will do this step by feel only, once it is inserted grab the 7/16" wrench and carefully spin out the bolt.
This took me approximately 20 minutes to complete from start to finish.
**Now I have to figure out how to wind a new rope. I have never done that before. Any tips would be great. I saw the tip earlier in the post, Thanks.... However I still don't quite understand, sorry!!
Here are a few pics of the process.
Good luck!!
Custom made tool to get to the bottom two bolts on the recoil housing.
I took a 3/8" drive 5mm allen socket purchased from Bomgaars, then I took a 38" x 1/4" adapter and put into the 5mm socket. I then took a 4" frinding wheel and ground the 1/4" adapter edges so it wasn't round anymore. I ground it so it had 4 flat sides and so a 7/16" wrench would fit over it.
You will need to carefully inseret the 5" socket with the 1/4" adapter into one of the two bolts that are hidden underneath. You will do this step by feel only, once it is inserted grab the 7/16" wrench and carefully spin out the bolt.
This took me approximately 20 minutes to complete from start to finish.
**Now I have to figure out how to wind a new rope. I have never done that before. Any tips would be great. I saw the tip earlier in the post, Thanks.... However I still don't quite understand, sorry!!
Here are a few pics of the process.
Good luck!!
When rewinding the coil spring in the pulley, no need to remove the rope. if there is not enough clearance to pull a small section of rope out between the pulley and the housing, just cut out a section of the plastic pulley big enough to fit the rope out, wind the pulley, then pull the slack in the rope out.
