Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 110 / 289

GENERAL INFORMATION
3.52
A
16. Slowly and carefully remove reel from recoil
housing making sure the spring remains in the
housing. Inspect the reel hub and bushing (A) for
wear.
17. Unwind rope and inspect for cuts or abrasions.
18. Inspect drive tab on hub return spring for damage.
To remove hub return spring, hold outer coils in
place with one hand and slowly remove spring
one coil at a time from the inside out.
19. Pull knot out of of recoil reel. Untie knot. Remove
rope from reel.
RECOIL ASSEMBLY
CAUTION: Be sure to wear a face shield and eye
protection when performing 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 at right.
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 ( PN 2871423 ).
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.
Open end here
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.
6. Apply downward pressure on the reel and rotate
counterclockwise approximately 6-7 turns to
pre-wind the spring. Continue rotating
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. Reinstall recoil housing using a new gasket. Seal
stator wire harness grommet with RTV silicone.