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How do you remove recoil housing assembly from 2003 Polaris Pro X 440 Fan to fix the broken cord. Took all bolts out but no room to remove recoil

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FIX THE RECOIL CORD ON A MOD. 116.23613300


Many times there will be a few screws to remove the recoil assembly. Once that is off looking at the bottom side should indicate with arrows, etc the direction the assembly turn and possibly how to wind the cord. Get a new cord or reuse old one if long enough. Reassemble same way you took it apart in reverse.

Nov 25, 2014 | Garden

1 Answer

I have a 22in self propelled, how do i change the pull cord


Remove the motor shroud encasing the pull cord assy. What I do is turn the shroud over, leave the spring in it's slack position and gather up the two broken pieces of string. I lay then down in a circular motion on top of the recoil spool until the string is all coiled up, counting each loop made. That and once more is how many times you'll need to wind that spool up. When you are done winding, "round up" to make the hole in the spool meet up with the hole in the recoil housing. Once you're there, get a medium sized flat-head screwdriver and wedge it between the spool and the housing, hindering the spool from unwinding. Wedge it good. Melt the end of the new pull cord and begin outside the housing and feed the string thru the eyelet on the recoil housing. Keep feeding it ( recoil housing still upside down ) thru until you visibly see it pass thru the eyelet and into the hole of the spool. You may need to use a small pick to grab it and pull it home. Once it's out, it's not over. Pull enough string thru to tie a double-loop knot. When you're satisfied with the strength of the knot, reach down and grab the string, holding it tightly. Next reach in and pull the screwdriver loose. Nothing should move-you're holding the string. Hold the shroud with one hand and let the string slowly pay into the recoil spool. Bolt the shroud back on and go!

Sep 23, 2013 | Poulan Pro " Pro" Self Propelled Mower

1 Answer

96 polaris atv fix starter


The recoil (pull cord start) cover should be removed and the reduction gear drive assembly needs to be inspected for broken/worn components. As this unit is responsible for turning the flywheel to spin the engine over. This construction on these units has three basic parts mechanically, the starter, the reduction drive gear, and the flywheel. Something is not aligned or meshing together.

Dec 16, 2011 | Polaris ATV

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My pull cord on my polaris ind xlt broke can i put it back on


YOU WILL HAVE TO REMOVE YOUR RECOIL TO PUT A NEW PULL CORD IN. THIS IS DONE BY REMOVING THE EXHAUST THAN REMOVE YOUR RECOIL ASSEMBLY. BE SURE TO WIND THE RECOIL BEFORE INSTALLING YOUR NEW PULL GORD.

Dec 20, 2010 | Polaris New Genuine Polaris Snowmobile...

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How do i remove the fly wheel on 2003 polaris 600 sportsman


remove the recoil cover bolts, then pull the recoil cover off exposing the flywheel. Remove the nut from the center of the flywheel (use an impact) along with the washer. At this point you will need a flywheel pullter. You can get one at harbor frieght for about $15.00 or you can usually rent one at Autozone. Do not use the "claw" type of puller as you change damaged the ring gear. Get the type that has a center push bolt/shaft and three holes for various types of bolts. Find the bolts that fit into the three bolt holes surrounding the nut on the face of the flywheel. Careful not to insert the bolts to far as you can damage the stator coil behind the flywheel. Good luck

Dec 10, 2010 | Polaris ATV

1 Answer

The pull cord on my poulan pro weedeater will not


You have a broken recoil spring. Dis-assemble (pull-off) the recoil housing and check for proper dog alingnment, broken spring, or something jammed between recoil sprocket and engine block.

Apr 27, 2010 | Garden

1 Answer

Oil and torque question for Polaris sport 400l (aka trailblazer)


You do not put oil in the recoil housing, the drain bolt is for draining water that gets in there if you drive through water. The oil you seen could have been put in there to lube the moving parts when it was apart at a an eariler time.The bolt at the top is to to do a visual inspection for.

Apr 01, 2010 | Polaris ATV

1 Answer

Broken recoil start on tecumseh 6.5 hp


broken cord? remove bolts holding recoil housing.lift housing straight up,you may have to wiggle it a bit.turn housing over,remove any cord thats left,note how & where it connects to the spool.wind the spool [and consquently the spring under it]in the direction the cord would turn it as pulled when starting.hold spool tight.thread new cord through hole in housing.let spool turn back just enough to attach new cord.hold cord & housing,let spring "re-coil" cord slowly.check for smooth operation.replace housing.you may need to pull cord slightly to align 'square' shaft w/hole in spool.only after you are satisfied with the operation of it adjust length of cord by pushing excess cord through the handle,tie a new knot,then cut off excess,if any.

Sep 21, 2009 | Garden

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Handle ripped off Mantis tiller


Good job on the cord replacement. Most people take the cover off the spring and then find out it is nearly impossible to get the spring tension set. I have personally repaired dozens of these cords that have been messed up by owners that did that.
If anyone has this problem, just do what this post says...remove the assembly and turn the pulley until you can get to the part of the cord that is broken...grab the end that is broken after you get it out of the opening with a vise grip and pull the cord out fully and lock the recoil spring with a vise or vise grip (but don't crush it)...then replace the cord and hold the end of the cord pull fully extended and remove the lock and allow the spring to recoil...and reinstall the assembly.
Simple, but THINK before you take the housing apart. It is REALLY TOUGH to reset spring tension properly.

Apr 26, 2009 | Mantis 2-Cycle Tiller

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