Determine the direction the rope needs to be wound on the reel. Most snowmobile recoil ropes are 6 feet long. Set the recoil housing and spring aside during the next step. With a hand over the spring, it will slowly unwind but remain inside the ridge. While holding down on the spring with firm pressure from a gloved hand or block of wood, slowly and gently release the locking pliers.
96 INDY 440 FULL
Now set the spring in the recoil housing with the full coil inside the housing’s raised ridge, and secure the outside hook of the spring on the tab in the recoil housing ridge.
96 INDY 440 FREE
With the pliers securely locked and holding the spring, remove the screws from the block of wood to free the spring from the jig. After the whole spring is wound, hook the end of the spring on the third screw.Ĭlamp a locking, needle-nose pliers on the spring to prevent the spring from un-winding. Wind the spring one rotation at a time, keeping the coils tightly wound. Make sure you wind it in the direction determined in Step 7. Hook the inside spring hook on the screw and wind the spring around the center screw and the screw the spring is hooked to.
96 INDY 440 INSTALL
Install three screws in a roughly 16-inch 2-by-4 piece of wood. Now make a jig to make it easier to wind the coil spring. The arrow should point in the direction the rope travels when it’s being pulled out of the recoil. Here’s a tip: Visualize an arrow on the inside end of the spring. The spring needs to be installed so it’s wound under tension when the rope is pulled out of the housing. Step 7: Determine the direction of rotationīefore the coil spring can be installed, determine the correct direction of rotation for assembly. Remove this washer, clean it, and reinstall it with a small dab of clean grease on the washer face. With the plastic reel removed you’ll see a fiber washer under the reel this is to reduce friction. Replace components that are damaged, and start the assembly process. The spring may have a broken hook on the end, or it might have popped out of position, which is usually caused by a worn part.
96 INDY 440 CRACKED
Inspect the tabs of the reel to make sure they aren’t worn, cracked or broken. However, this is the time to inspect for other problems. Obvious problems before getting to this point are a broken rope or broken coil spring. If you did not know the problem with your recoil up to this point, you should be able to identify it now. Remove the plastic reel, but be careful because the spring is likely still under some tension. These components vary a little in construction from brand to brand, but they all perform the same function. Note the orientation of these components for reassembly when the recoil repair is complete you should draw a sketch or take a picture. Remove the nut on the center of the assembly. Now you’re ready to disassemble the recoil. At some point, the recoil will retract until the spring loses its tension on the rope. If the rope is still intact and is under spring tension, let the rope pull through the hole in the housing and inside the recoil as far as possible while holding the rope. Place the recoil on a flat work surface with the guts facing up. Recoils contain small parts that are under a lot of tension. If cracks are severe, the housing might need to be replaced.īefore you start to disassemble the recoil, put on a pair of safety glasses. Inspect the mounting holes on the recoil housing for cracks or other damage. Untie the rope from the grab handle and pass it through the guides, tie a loose knot and remove the assembly from the sled. If the recoil rope is still attached to the handle, you’ll want to prevent the rope from retracting into the recoil.
If the recoil rope is broken, the recoil can be removed from the machine at this time. There will usually be enough clearance between the engine and chassis to allow easy recoil removal, but in some cases there might be a frame rail or chassis component in the way and the engine will need to be lifted off of the motor mounts to provide access. Twist out the screws that fasten the recoil housing to the engine. Step 1: Unbolt recoil assembly from engine
Variations exist among the components, but they perform the same function and the principles apply across the board. We repaired a recoil from an Arctic Cat for this story, however design and construction is similar among all manufacturers. The whole job should take about one hour. Once you can make the repair, follow these steps. Fortunately, their intricate parts can be tamed with the right tools and determination to get the job done.Ī broken recoil rope or failed components seem to happen at a bad time or place, and it isn’t an easy trailside fix. The complexity of rewind starters is highly underestimated. Recoils look pretty simple hanging on the side of the engine, but don’t assume.
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