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144
REC OI L STA
RTER
Removal
/In
st all a tion
I.
Place the ATV
on a
level sur face and
apply
the
parking bra
ke. Bloc k the
wheels
to
keep
it
from
rol
l-
ing
in
either
direction .
2
. On
1998
and
later
mod
el s. rem o ve
the
rear
aux
il-
iary brake master cy
linder and rear
brak
e
assemb
ly
(A
,
F
ig u re
2
1)
as
desc
ribed
in
Chapl
er
Fourt
een.
Do not
disco
nnect
the hydra ulic brak
e
line,
j
ust
move
the
muster
cylin
der
out of
the
way.
3. Remove
the bo
lts
securing
the recoil
slarter
(13,
Fig u re
2
1) to
the
cra
nkcase,
then
remove the recoil
starter and gasket.
NOTE
The electric
starter
reduction drive
assembly should remain with
the
en-
gine.
One
end
of the
reduction
drive
assembly
pivots
ill
the rewind starter
housing.
4. Insta
ll
the
recoil starter
asse
mbly
and
lighte n
the
mounting
bolt
s
to
the
torque spec
ification listed
in
Table
1.
D
isassembly a
nd Sta rter
Rope
Removal
Refer to
Figure
22.
I.
If the
rope
is
not broken,
pull
it from the
housing
and
tie a loose knot to
keep
the
rope
from
rewin ding.
2.
Removethe anchor from the
starter
handle. untie the
knot
and remove
the
handle
from
the end
of the rope.
3. A
llow the
rope to
wind slowly
into the housing.
4
.
Remove
the
center
bolt (Fig u re
23
).
5.
Remo ve the
friction
plat
e
(A
,
Figure 24
),
ratche t
pawl (B)
,
paw
l
spring (C) and
friction
spring (D)
.
CAUTION
The recoil
spring
is
under
pressure
and
may
j
ump from
the housing
dur-
ing
disassembly. Its
edges
are
sharp
and may
c
ut or
cause
eye
injury. H
-
e ar
hand ami
~l'e
protection when
disas-
sembling and
assembling.
6. Care fully lift the
starter pulle
y
and
rope
from
the
hou sing
.
Make sure the recoi
l
spring
rema ins
in
the
starter hou
sin
g.
7.
Unwind
and
remove
the
rope
from
the
starte r
pulley
if rep lacement is necessar y.
CIIAPTER FIVE
8.
To
remove
the recoil spring, invert the starter
ho
using
and
tap
it
on
a
so
lid
surface.
The
spring w
ill
fall free
and
unwi nd
inside
the
starter
ho
using .
lnspectiun and Assembly
I.
Clean all
pans
in solvent and
dry them thoroughly.
2. Insp ect the
fri
ction
plate
(A,
Figure
24)
,
ratchet
pawl
(B)
,
pawl spring (C)
and
friction
s
pring (D) for
damage.
The frictio n spring sho uld grip
the
friction
plate
securely,
3,
Chec
k the rope
for
frayi
ng
or
ot
her
damage.
4
. Inspcctt
he
tab
s
at
the
end
s
of the
recoi
l spring.
SA
.
Rein stall the
old
recoil
spr ing
as
follows:
a.
Hook the
out
er
end
of
the
recoil
spring
in
the
ho
usin
g,
b.
Wind
the spring into
the housing
in a
counter-
clockwise
direc tion
until the
s
pring is com-
pletely in
the
hou
sing.
Hold
the
co
ils in p
lace
while
w
inding
the spring
into
the
hos
ing
.
c.
Th
e instal
led
spring should
be
positioned
as
shown in
Figure
25
.
513.
New reco
il
springs are held
co
mpressed
by
a
w
ire.
Usc the following
instructions to
install
the
new
spn
ng.
a.
Posit
ion the
new spring
in
the
ho using so that
it
spirals inward in a count erclock wise di
rec-
tio
n
and attach the
outer
end of
the
spri ng to
the
housing
,
b.
Hold the spring in
place
and
c
ut
the
retai
ning
w
ire.
Th
e install ed
spring should
be posi-
tion ed
as
show n
in
Figure
25.
6.
Lubri
cate
the
spring
w
ith
a
light,
low-temperature lubricant such
as
Polari
s
Cable
Lube
(part
No.
28705 10).
7.
If
the
rope
is
detached from
the
pulle
y,
allach
the
rope as foll o
ws:
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