Pull start snapped... need some advice - HCS Snowmobile Forums

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Old 01-30-2008, 11:43 AM   #1 (permalink)
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Itís one thing after another with my sled this week. I broke the starter rope recoil. The rope then snapped but my main question is do I need to take off the exhaust to get to the housing?

Also how difficult is it to change the spring inside? Does anyone have a diagram of the starter?
I called a shop locally here MA and they will fix it cheap if I just bring the housing.... if I bring the whole sled they are going to charge about 150 for it. Is 150 worth it or is it something easy to do and they are taking me for a ride?

I have a 2002 Polaris XC SP 800, itís my first sled so this website is great.

thanks.
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Old 01-30-2008, 11:54 AM   #2 (permalink)
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Itís one thing after another with my sled this week. I broke the starter rope recoil. The rope then snapped but my main question is do I need to take off the exhaust to get to the housing?

Also how difficult is it to change the spring inside? Does anyone have a diagram of the starter?
I called a shop locally here MA and they will fix it cheap if I just bring the housing.... if I bring the whole sled they are going to charge about 150 for it. Is 150 worth it or is it something easy to do and they are taking me for a ride?

I have a 2002 Polaris XC SP 800, itís my first sled so this website is great.

thanks.[/b]
Rather easy to fix yourself, if you pull out the rope sheave very carefully, the spring will stay in the housing, otherwise you may swear a bit getting the spring back in.

Don
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Old 01-30-2008, 12:40 PM   #3 (permalink)
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You can get the recoil housing off with the motor in the sled, just pull the exhaust off and you'll need a 10 mm swivel socket. If you got any miles on it get a new water pump belt while you're at it. Cheap insurance. Also check the water pump shaft for looseness side-to-side(bad brg), might be time for a rebuild.
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Old 01-30-2008, 02:25 PM   #4 (permalink)
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you cal always wrap a belt of strap around your clutch and pull that. i did that for a long time untill i decided to put a new rope in lol
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Old 03-31-2008, 03:21 PM   #5 (permalink)
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Just had this happen to me this weekend. I used the string around the clutch trick to keep riding.

What do I need to fix this? The rope did not snap out of the housing, it just pulled out and will not recoil. Is there a spring that needs to be replaced inside the housing? Is it a Polaris only part?

Thanks in advance.
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Old 03-31-2008, 03:26 PM   #6 (permalink)
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Sounds like the recoil spring broke, replace the recoil rope too, while you're in there.. I think you can get an aftermarket one.. Shouldn't take more than 15 minutes to replace, once you get it off the machine..
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Old 03-31-2008, 07:17 PM   #7 (permalink)
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If its a "Big block" twin,ie 600 nonves, 700 or 800, do NOT ride it with a broken recoil rope! At least not very far.

When the rope breaks, it will eventually find its way into the water pump belt and derail/break it.
Causing you to lose cooling - and oil.... If you don't notice the templight right away, it may cost you an engine...
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Old 03-31-2008, 10:57 PM   #8 (permalink)
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I don't think you can do it without taking off your exaust. At least it's way easier if you do take it off, not a big deal just some springs (much easier with a spring puller).

Take off the exaust, a few 10mm bolts and replace the rope. Wind it up the same way you would a chainsaw or law mower or whatever. That's what the little notch is for in the pulley, so you can wind the tension back up.
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Old 04-01-2008, 12:11 AM   #9 (permalink)
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last time i broke a rope i took the exhaust and housing out..ended up taking off the wrong bolt and the spring came flying at me...thank god i have the handiest teacher ever...i gave him ten bucks and he put the spring and new rope in and i picked it up an hour later a shop was charging over $50 to put the spring back in...if you accidentally let the spring go flying find someone to do it...its one of them parts some people can fix and some cant...personally i cant...my teacher did it in about 5 minutes once he started working on it..goodluck!
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Old 04-29-2008, 09:16 PM   #10 (permalink)
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Just remembered that I need to do this before I store the sled. Where can I order a new rope and spring online?

Thanks!

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