How to Fix a Polaris Pull Rope

Some recoils are a back-up system for an electric starter on Polaris watercraft, snowmobiles and four-wheelers. The pull rope, or recoil system, used on Polaris snowmobiles, watercraft and four-wheelers is made of nylon rope and is manufactured to last a long time. They usually fail because the mechanism used to attach them to the T-handle or recoil pulley cut into the rope and caused it to fray. When replacing the rope, be sure to use a good quality nylon rope made especially for recoils.

Things You'll Need

  • Safety glasses
  • Wrench set
  • Scissors
  • Lighter
  • Nylon recoil rope
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Instructions

    • 1

      Remove the recoil cover from the engine by removing the attachment bolts on the cover.

    • 2

      Cut a piece of recoil rope of the same size and quality, using a scissors . Use the old pull rope to determine the proper length. Heat one end of the nylon rope with a lighter to melt it. Dip your thumb and forefinger into water and quickly pinch the end of the melted rope to form a smooth rounded end while it's still hot. Repeat on the other end of the rope. This prevents the rope from fraying.

    • 3

      Place the recoil cover so the inside pulley is facing up on your lap.

    • 4

      Locate the old knot or depression where the rope's knot seats into the pulley. Pull the old knot from the pulley if it still remains. Tie a double knot close to one end of the new rope.

    • 5

      Hold the center pulley of the recoil so it can't turn. Rotate the recoil cover in the direction that tightens the recoil spring under the pulley, while holding the center pulley still. The cover is normally rotated in the opposite direction that the pulley turns when the pull rope is pulled.

    • 6

      Rotate the cover until you feel the spring tighten, then back it off until the knot depression in the pulley aligns with the exit hole of the recoil cover.

    • 7

      Feed the rope through the knot depression hole in the pulley and out the exit hole in the cover while still holding the cover and pulley rigid. When the rope exits the cover, feed it through the recoil T-handle and tie a knot or double knot to hold it. Pull the entire rope out of the recoil to seat the knot in the pulley's depression. Allow the spring to turn the pulley slowly as it winds the cord back into the pulley.

    • 8

      Pull the newly installed recoil rope as you would if you were going to start your Polaris. The recoil should pull out smoothly and recoil back into the cover with the spring.

    • 9

      Align the recoil pulley to the crankshaft of the Polaris and reinstall the cover. Reattach the cover bolts and tighten.