Recoil Pulley; Rope Removal And Installation - Polaris 340 LX 2007 Service Manual

Engine Systems

RECOIL PULLEY

Rope Removal and Installation

NUT
FRICTION PLATE
RATCHET SPRING
488 SHOWN - ALL MODELS SIMILAR
CAUTION
Recoil spring under high tension. Always wear eye
protection when working with recoil housing
components.
1. With the recoil housing removed from the engine, un-
tie any knots (handle) in the recoil rope and allow the
pulley to slowly unwind.
2. Remove the nut, friction plate, friction spring, ratchet
and ratchet spring from the pulley.
3. Lift the pulley straight out of the housing making sure
the spring is no longer connected to the backside of
the pulley.
NOTE: If all of the recoil spring tension was removed,
the spring should stay inside the housing when the
pulley is removed.
4. Inspect all components for signs of abnormal wear
and tear. Replace components as required. If
replacing the rope, tie a small square knot at one end.
Push the knot firmly into the pocket on the pulley.
5. If the pulley recoil spring was removed during
disassembly, install the spring by spiraling the spring
counterclockwise toward the center of the housing.
6. Lubricate the center shaft and spring with Premium
grease.
7. Wind the rope counterclockwise around the pulley as
viewed from the ratchet-side of the pulley.
5.12
FRICTION SPRING
RATCHET
RECOIL SPRING
ROPE
TAB (ENGAGES INSIDE PULLEY)
9923396 - 2007-2012 EDGE/Widetrak LX Service Manual
©2011 Polaris Sales Inc.
TAB (ENGAGES INSIDE HOUSING)
RECOIL PULLEY
8. Pass the end of the rope through the hole in the
housing. If the rope guide was removed from the
housing, reinstall it before attaching the rope handle.
9. Slide the pulley down the center shaft and into the
housing making sure the recoil spring re-engages the
pulley tab.
10. Install the ratchet spring and ratchet into the pulley
face. The ratchet spring leg fits in the notch on the
ratchet and holds the ratchet in (retracted).
11. Install friction spring with one leg inserted in the
bottom hole on the ratchet.
12. Install nut and torque to 5 ft.lbs. (7 Nm).
13. Pull rope out to its full extension and align pulley notch
with rope hole in housing.
14. Using a needle nose pliers or hooked wire, pull a loop
of rope through the notch in the pulley.
15. Prevent the rope from being retracted by tieing a knot
in the rope on the outside of the housing at the rope
guide hole.
16. Wind the recoil pulley counterclockwise until the
spring begins to bind. Unwind the pulley clockwise two
revolutions.
17. Pull on the rope to disengage it from the notch in the
pulley. Un-tie the knot in the rope and allow it to retract
into the housing.
18. Pull on the handle to verify proper operation.
ROPE GUIDE (HOLE)