I ran into a lot of breakage this first weekend out. The knot must have came out on the recoil, and it got sucked back into the housing, and the machine quit suddenly out on the trail, like I hit the kill switch. The machine isn't seized or anything, it spins freely. I couldn't get the recoil cover all the way off (missing ratchet reducer, err), but I was able to pry it open, and saw that the extra rope appeared to go into the motor behind the magneto I think. What kind of components could have been damaged by this, stater, some plugs getting ripped or knocked off?

Obviously your not stuck on the trail right now, eh? Take the cover off and see what happened.

I made a howto on recoil's. And lucky you (not that it mattered), I did it with a 96 ZRT 600.

http://www.snowmobilefanatics.com/forum/to...94/display.aspx

Snowmobile is up North, I didn't have the proper tools up there (someone used my socket set and broke the reducer). Just looking for good guesses, before I tear it down, looking at the parts manuals, it looks like the timing sensor wires probably got tangled and disconnected or something. It was definitely electrical, and that is the only thing down there I think would be hosed by extra rope dangling around in there.

Yes, this is on my 2001 ZRT 600, I've rewound the coil a few times on my 96, the 01 is the same deal, all AC's to 04 are apparently. I bought the 2001 used, and the fellow who had it before me rewound it incorrectly apparently, as it was all sucked back into the recoil case, that actually shouldn't happen, the zero recoil position should leave 20 inches or so outside the case.