Oil Pipes; Recoil Disassembly/Inspection - Polaris SPORTSMAN 400 2003 Service Manual

OIL PIPES

Install the oil pipes with new sealing washers. Tighten
all bolts evenly to specified torque.
Oil Pipe Bolt Torque:
20 ft. lbs. (27 Nm)
RECOIL
DISASSEMBLY/INSPECTION
CAUTION: The recoil is under spring tension. A face
shield and eye protection is required during this
procedure.
Replace any parts found to be worn or damaged.
REMOVE BOLTS AND
RECOIL HOUSING
10. Pull recoil rope so it is extended approximately
12-18². Check handle c-ring for proper tension,
and the handle for cracks or damage which may
allow water or dirt to enter the recoil housing
through the rope. NOTE: The handle must seal
tightly on the recoil housing to prevent water from
entering.
A
11. Remove center bolt from recoil friction plate (A).
12. Inspect plate for wear or damage. Inspect plate
friction spring for wear, damage, and proper
tension. The spring should fit tightly on friction
plate.
13. Remove ratchet pawl with spring and inspect.
Replace spring or ratchet pawl if worn, broken, or
damaged.
NOTE: Long arm of spring engages reel. Short end
against pawl.
14. Hold reel firmly in housing. Pull rope handle until
12-18² of rope is exposed, and hold reel in place.
15. Place rope in notch on outer edge of reel.
Release tension on hub and allow reel to unwind
approximately 6-7 turns until spring tension is
released.
ENGINE
3.51