Recoil Assembly - Polaris Trail Boss 330 2003 Service Manual

ENGINE

RECOIL ASSEMBLY

CAUTION: Recoil is under spring tension. A face
shield or eye protection is required during this
procedure.
To install a new spring:
1. Place spring in housing with the end positioned so
the spring spirals inward in a counterclockwise
direction. See photo.
2. Hold spring in place and cut retaining wire.
To reinstall an old spring:
1. Hook outer tab in place in recoil housing and wind
spring in a counterclockwise direction one coil at a
time while holding the installed coils in place.
2. Lubricate the spring with light lubricant such as
Premium All Season Grease.
To complete recoil assembly:
1. Route rope through guide bushing in recoil
housing and into reel. Tie a secure knot in end of
the rope.
2. Wind rope counterclockwise onto the reel, as
viewed from ratchet side of reel.
3. Lock rope into notch on outer edge of reel.
4. Apply a small amount of grease or equivalent to
the center post of the housing and the bushing.
5. Install reel into housing making sure the spring
drive tab on the reel engages the spring and the
reel is fully seated in the housing.
3.44
Open end here
6. Apply downward pressure on the reel and rotate
counterclockwise approximately 6-7 turns to
pre-wind the spring.
counterclockwise until rope on outer edge aligns
with rope guide bushing.
7. Release rope from notch and allow reel to rewind
completely. If more pre-wind is required, place rope
in notch and add additional turns of pre-wind.
8. Install ratchet pawl and return spring, with long leg
of spring engaged in reel.
9. Reinstall friction plate.
NOTE: The friction plate must be positioned with
both end tabs of the friction spring opposite the
ratchet pawl.
10. Torque friction plate retaining bolt to 5-6 ft. lbs.
(7-9 Nm).
11. Apply Crankcase Sealant (PN 2871557) to the
recoil housing outer edge.
housing. Seal stator wire harness grommet with
RTV silicone.
Continue rotating
Reinstall recoil