Arctic Cat ZR 120 Service Manual page 28


NOTE: The engine must be removed to access the
recoil starter (see Engine section).
REMOVING/DISASSEMBLING
! WARNING
Always wear safety glasses when servicing the recoil
starter.
1. Remove the cap screws (A) securing the recoil
starter to the engine cover.
2. Pull the rope out of the housing (noting the direc-
tion in which the rope is wound for assembling)
and align with the notch in the roller; then release
the spring pressure on the reel (B).
3. Remove the knot from the end of the rope; then
remove the shoulder screw (C) securing the drive
plate (D) to the reel and remove the plate.
4. Mark the ratchet arms (E) for assembling purposes;
then remove the ratchets and account for the friction
spring (F).

NOTE: The ratchet arms must be installed in their
respective positions.
5. Slowly remove the reel. Account for the spiral
spring (G).
! WARNING
Exercise extreme caution when removing as the spiral
spring may disengage and cause severe injury.
INSPECTING
1. Inspect the spring retaining notch in the recoil
housing and inspect the loop of the spring for wear
or cracking.

NOTE: Note the orientation of the spring for assem-
bling purposes.
2. Inspect the flat areas of the reel for wear.
ASSEMBLING/INSTALLING
1. Install the reel assembly with rope wound in the
appropriate direction (noted during disassembling).
! WARNING
Exercise extreme caution when installing as the spiral
spring may disengage and cause severe injury.
2. Install the ratchet arms; then install the drive plate
and secure it with the shoulder screw. Tighten to
57 in.-lb.
3. Route the recoil rope through the rope guide of the
recoil housing and through the recoil handle; then
tie a knot in the rope.
4. Wind the rope counterclockwise 3-4 turns around
the reel; then secure the recoil starter to the engine
cover. Tighten to 96 in.-lb.
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