Polaris 2007 Sportsman 450 EFI, Service Manual

Page: 109 / 406

3.51
ENGINE
3
RECOIL
Recoil Disassembly/Inspection
Replace any parts found to be worn or damaged.
1. Remove bolts and recoil from the engine.
2. Pull recoil rope (if applicable) so it is extended
approximately 12-18" (30-46cm). 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.
3. Remove handle from the rope and allow spring tension on
recoil to relax.
NOTE: The handle must seal tightly on the recoil
housing to prevent water from entering.
4. Remove center bolt from recoil friction plate (A).
5. Inspect plate for wear or damage. Inspect plate friction
spring for wear, damage, and proper tension. The spring
should fit tightly on friction plate.
6. 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.
7. Hold reel firmly in housing. Pull rope handle until 12-18"
(30-46cm) of rope is exposed, and hold reel in place.
8. 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.
9. 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.
10. Unwind rope and inspect for cuts or abrasions.
11. 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.
12. Pull knot out of recoil reel. Untie knot. Remove rope from
reel.
CAUTION
The recoil is under spring tension. A face shield and
eye protection is required during this procedure.
A
A