Polaris FST IQ 2007, Service Manual

Page: 130 / 325

5.11
Engine and Cooling Systems
5
RECOIL ASSEMBLY
Rope Removal and Installation
1. With the recoil housing removed from the engine, un-tie
any knots (handle) in the recoil rope and allow the pulley
to slowly unwind.
2. Remove the nut, friction plate, friction spring, ratchet and
ratchet spring from the pulley.
3. Lift the pulley straight out of the housing making sure the
spring is no longer connected to the backside of the pulley.
NOTE: If all of the recoil spring tension was
removed, the spring should stay inside the housing
when the pulley is removed.
4. Inspect all components for signs of abnormal wear and tear.
Replace components as required. If replacing the rope, tie
a small square knot at one end. Push the knot firmly into
the pocket on the pulley.
5. If the pulley recoil spring was removed during disassembly,
install the spring by spiraling the spring counterclockwise
toward the center of the housing.
6. Lubricate the center shaft and spring with Premium grease.
7. Wind the rope counterclockwise around the pulley as
viewed from the ratchet-side of the pulley.
8. Pass the end of the rope through the hole in the housing. If
the rope guide was removed from the housing, reinstall it
before attaching the rope handle.
9. Slide the pulley down the center shaft and into the housing
making sure the recoil spring re-engages the pulley tab.
10. Install the ratchet spring and ratchet into the pulley face.
The ratchet spring leg fits in the notch on the ratchet and
holds the ratchet in (retracted).
11. Install friction spring with one leg inserted in the bottom
hole on the ratchet.
12. Install nut and torque to 5 ft.lbs. (7 Nm).
13. Pull rope out to its full extension and align pulley notch with
rope hole in housing.
14. Using a needle nose pliers or hooked wire, pull a loop of
rope through the notch in the pulley.
15. Prevent the rope from being retracted by tieing a knot in the
rope on the outside of the housing at the rope guide hole.
16. Wind the recoil pulley counterclockwise until the spring
begins to bind. Unwind the pulley clockwise two
revolutions.
17. Pull on the rope to disengage it from the notch in the pulley.
Un-tie the knot in the rope and allow it to retract into the
housing.
18. Pull on the handle to verify proper operation.
NUT
FRICTION PLATE
FRICTION SPRING
RATCHET
RATCHET SPRING
ROPE
RECOIL PULLEY
RECOIL SPRING
TAB (ENGAGES INSIDE HOUSING)
TAB (ENGAGES INSIDE PULLEY)
ROPE GUIDE (HOLE)
CAUTION
Recoil spring under high tension. Always wear eye
protection when working with recoil housing
components.