Polaris Sportsman 400, Service Manual

Page: 145 / 381

ENGINE
3.76
RECOIL ASSEMBLY
CAUTION: Be sure to wear a face shield and eye protec-
tion 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.
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.
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.
Open end here