Recoil Starter - Arctic Cat ZR4000 Service Manual

Recoil Starter

KEY
A. Cap Screw
B. Roller
C. Friction Plate
D. Cap Screw w/Washer
E. Pawl Activator
F. Pawl
G. Return Spring
H. Friction Plate Spring
I. Main Spring
741-373B
REMOVING
1. Tie a slip-knot in the starter rope below the console
and allow the rope to slowly retract against the
starter case.
2. Remove the knot at the handle, remove the handle,
and account for the handle cap; then thread the rope
through the bushing in the console.
3. Remove the cap screws (A) securing the starter
assembly to the magneto case; then remove the
starter assembly.
DISASSEMBLING
! WARNING
Always wear safety glasses and gloves when servicing
the recoil starter.
1. Secure the recoil starter in a vise.
! WARNING
During the disassembly procedure, continuous down-
ward pressure must be exerted on the reel so it does
not accidentally disengage and cause injury.
2. Rotate the roller (B) counterclockwise until the notch
of the roller is near the rope guide in the case. Guide
the rope into the notch and slowly allow the roller to
retract until all recoil spring tension is released.
! WARNING
Care must be taken when allowing the recoil roller to
unwind. Make sure all spring tension is released before
continuing.
3. While exerting downward pressure on the friction
plate (C), remove the cap screw with washer (D).
4. Slowly release the friction plate and lift the plate
with pawl activator (E) free of the recoil roller; then
remove the pawl activator from the friction plate.
5. Remove the pawl (F) and the return spring (G); then
remove the friction plate spring (H).
6. Carefully lift the roller free of the case making sure
the main spring (I) does not disengage from the case.
Account for the bushing.
! WARNING
Care must be taken when lifting the roller free of the
case.
7. Remove the main spring from the case by lifting the
spring end up and out. Hold the remainder of the
spring with thumbs and alternately release each
thumb to allow the spring to gradually release from
the case.
NOTE: Do not remove the main spring unless

replacement is necessary. It should be visually
inspected in place to save time.
8. Unwind the rope from the roller, untie the slip-knot,
and remove the rope.
CLEANING AND INSPECTING
1. Clean all recoil starter components.
2. Inspect springs and pawl for wear or damage.
3. Inspect the roller and case for cracks or damage.
4. Inspect the center hub for wear, cracks, or damage.
5. Inspect the rope for breaks or fraying.
6. Inspect the main spring for cracks, crystallization, or
abnormal bends.
7. Inspect the handle for damage, cracks, or deteriora-
tion.
ASSEMBLING
1. Hook the end of the main spring around the mount-
ing lug in the case.
2. Insert the main spring into the case; then wind it in a
counterclockwise direction until the complete spring
is installed.
NOTE: The main spring must seat evenly in the

recoil case.
3. Insert the rope through the hole in the roller and tie a
knot in the end; then wrap the rope counterclockwise
around the roller leaving approximately 20 in. of
rope free of the roller.
4. Apply low-temperature grease to the main spring and
hub.
5. Align the hook in the end of the main spring with the
notch in the roller.
6. Carefully slide the roller over the hub and engage the
spring with the roller; then install the bushing.
7. Install the return spring making sure the short leg of
the spring is properly installed in the hole in the
roller; then install the pawl making sure the return
spring is properly positioned in the notch of the
pawl.
8. Slide the end of the rope through the rope guide of
the case; then tie a slip-knot in the rope.
117