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Discussion Starter #1
Well heres the story from my exhaustive research on pull cord fixes and a blurb on each one.

1 - AC fix alone.
Worst of the bunch. I does get the rope off of the plastic but not the brake housing. If you don't pull it directly straight it will hit the plastic. The only way to pull it straight is to turn the handle bars all the way left. I looks really F'ed up also. Cost: free with purchase of $7,000.00 sled. You may have to wait for dealer to get them.

Opinion: A quick fix that will disappoint in the long run.

2 - 1/4" x 2 eyebolt with AC fix.
Got the rope off of the brake and away from the frame rail. With the AC fix it is all right but still has the problem of hitting the plastic if not pulled straight. Cost: $2.25 for SS hardware. Pain in the ass to put on with big fingers.

Opinion - A cheap fix that will get you through but you're going to replace the rope sooner or later.

3 - Wheel type fix posted on HCS.
This works pretty well but has two drawbacks. 1st and this is major. You have to have access to a machine shop to make it well and to fit perfectly. Took my guy a couple hours to make and about two minutes to install. 2nd, the rope would come off the wheel if I pulled wrong and tore it up worse than the plastic did. That could be cured with a rope stop like on a cable weight pull. Best part is you don't have to take the rope handle off to install. That knot is a B*#@$!. Cost: about $5.00 in Materials and $100 in labor if you had to pay for it. Would benefit from some good engineering.

Opinion - An ingenious idea not available to the common man. Will work well if you can build it.

4 - Use some 5mm spectre cord.
This rope used for rock climbing, does not fray and is strong as hell. It will probably outlast your sled. I would put this on regardless of what you do. The drawback is that it is stiffer than the nylon rope so it is alot harder to get into the recoil. If you have not put a recoil rope in before take it to someone who has and watch what they do. A good AC dealer may put this rope in for you when they do your fix. Cost: You need 7 feet at roughly $.35 per foot. Available at any climbing store or at REI.com

Opinion - It will work by itself but will shine with any other fix.

5 - The Outdoor Shop tube
I have not received my tube yet. I was on the first to order so I should get it soon. After working with all of these, I believe that this one will be the best. Dan has told me it goes through the plastic to protect it so that solves one problem and where it mounts (same place as the eyebolt) will solve it hitting the brake. The only drawbacks I see is that it is not a production item but a handmade piece that may have some fit variances. The concept is simple and the machining should be relatively easy so I wouldn't think this will be too much of a problem. Cost: $30 for the part. May be difficult to get mounted. (See eyebolt and big fingers) You may also have to wait because it sounds like the demand it high.

Opinion - Hard to have one without the part but I believe this will be the best of all.

There it is. A whole lot of nights with my wife asking me "Haven't you fixed that yet". As a summary I would recommend calling Dan and getting an Outdoor Shop tube and putting in the Spectre cord. You will never worry about the rope pull again.
 

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I nominate this for the "post of the week" award!!! Very nice report Snowman! Thanks for taking the time to do all your extensive testing, and for sharing your results with us. Please DO let us know how your FINAL fix works though. I'm very close to calling the Outdoor Shop to order one of their tubes! -- roy
 

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Guys, I made this fix from a large clip/pin (the one that holds your receiver bolt from backing out). It works great: never touches the plastic at any pull angle and keeps the rope from the bottle, brake and frame. very cheap too!!
 

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It does not have a problem from resting on the brake. The problem is where it comes through the hole to the handle. It is not rocket science, and it is getting way over played. Time for some riding instead of bitching about this sniveling shit. Time to emberase the OFF BRANDS. If we could only get some snow!
 

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Is the tube that Dan sells from a ZRT. It looks the same as what I had on my 600
 

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Here is the part # from a 96 ZRT 600
0708-031 GUIDE,RECOIL ROPE-WELD'T
 

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Mine is getting the AC update done on it.
 

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Discussion Starter #10
Got a note from BY AC and he made a good point. I did not review a part he made, I looked at his picture and built the wheel pulley fix myself. My engineering skills are lacking and it is hard to build from a low res picture. His engineering skill are obviously beyond mine (He thought of the thing) and his would probably work much better than mine. I did not mean to say his design was bad, just beyond what those of us with limited skills could build.

Sorry BY AC.
 

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I fixed mine a while ago using a plastic tube that runs from the recoil to the pull
handle . It was cheap ,quick and easy to do . So far no problems and my rope
still looks new ! You can get this from a hardware store . My son used
1'' black plastic water pipe off a 50' roll we had . :D
 

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Discussion Starter #13
Dan told me he shipped it yesterday. I should have it installed tomorrow night. He was waiting to ship me some backordered stuff that is still backordered. I'll post after I install it.
 

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I'm in the process of making some out of aum. tubing, 1/2 " od. Welded to a bracket that mounts where AC's fix does. Flared at both ends & sticking slightly through dash , should work good with heavy rope, green of course!
 

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made one up like the outdoor shop welded it to arctics cheap bar fix after grinding it to accept the tube.used spectre 5mm cord.looks good and works good B)
 

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Discussion Starter #17
Got The outdoor shops fix and installed it. It works as advertised. I have the spectra cord in also and no marks or frays at all. Only pulled it a few times though. I will say that before and after I decided on this fix, I have seen some very ingenious ways of making this problem go away. ACs is a get it out quick fix but you would think they would have been a little better. It is pretty cool that this site exists and lets us make a educated decision. Hats off to the people who run it, post on it and especially the people who think up solutions and share them.
 
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