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Discussion Starter #1
I have a 97 Indy Trail Touring that I am rebuilding and the starter recoil assy was disassembled. I cannot figure out how to get it wound and installed without it springing back at me when trying to install it. Is there a trick that any of you know about.

I may just put it back on without the pull cord assy since it has electric start but I would hate to have the battery go dead on the trail.
 

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Alex
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there is no trick that I know of (other than having 5 hands helping you)..... Recoils are the nemesis of all DIY mechanics of any small engines.
 

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Start by cutting yourself about 6 ft of starter rope.
use a match and burn the end of the rope and then while it is burning use a shop rag to shape the melted end into a point. Repeat the process on the other end of the rope as well.

Tie a single knot in one end of your rope , It is easier if you have a vice to fasten the recoil housing to so it does not move around on you, once the housing is secure wind the recoil up by hand until it is wound up tight. You will feel it stop. now allow it to unwind back until the rope hole in the pulley lines up with the rope eyelet in the housing. Usually around a 1/2 turn. Now while still holding the pulley pass the unknotted end of your rope through the pulley and then also through the eye in the housing.
Pull it alll the way through until the knot seats in the recess in the pulley and tie a loose temporary overhand knot somewhere around halfway down the rope which is now extending out from the recoil housing. This loose knot will allow you to slowly let the pulley unwind until the knot stops it from going all the way. Now you can pull the rope out a few times and make sure the recoil is returning like it should and nothing is binding. Install the recoil housing on the sled and pass the rope through any eyelets it needs to go through and attach your starter handle. Use a good double knot to be sure the handle does not come off. Lastly untie your temporary overhand knot and you are done.
 

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Repair Shop Owner
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I just did a recoil on a 82 Polaris TXL340 and there a PITA!! What I did was take a board and put 5 nail's that same diamator as the recoil housing and rap the inside the nails. Then I took a couple needle nose vice grips and clamped the spring and tranfered it to the recoil housing. Just make shure you have the spring lined up the right way so it will recoil the rope the right direstion or you will be doing it again and cussing the hole time!! Don't ask me why I know this!
 

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Take it to a shop and spend the 10 bucks they are goin to charge you to install it.. i did it myself and apparently did it wrong, cruising down the trails the rope got sucked in, broke, handle went somewhere on the trail, and i was left staring my sled with a rope on the clutch.. now thats a bad day. just pay the 10bucks and have it done right.. just sayin
 

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King of the Universe
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There's sticky in the engine section how-to's
 

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Discussion Starter #8
Take it to a shop and spend the 10 bucks they are goin to charge you to install it.. i did it myself and apparently did it wrong, cruising down the trails the rope got sucked in, broke, handle went somewhere on the trail, and i was left staring my sled with a rope on the clutch.. now thats a bad day. just pay the 10bucks and have it done right.. just sayin
If I had a shop close by I would but I am in central Ohio, the closest shop is an hour away.
 

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Discussion Starter #10
The sticky in the Engine section How Too worked perfectly the first try. Hammer two nails approximately 1 inch apart, hook the center end of the spring on one nail and wind it up. Hold a piece of board on top of the spring to prevent it from popping up on you. Once you get it wound up tight enough to fit in the housing clamp a pair of vice grips on the spring to hold it together. Using the vice grips, place the spring in the housing making sure the outer hook connects with the housing. Slowly release the vice grips and the tough part is over. Now just reassemble the rope housing and done.
 

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Reverend Dennis
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The sticky in the Engine section How Too worked perfectly the first try. Hammer two nails approximately 1 inch apart, hook the center end of the spring on one nail and wind it up. Hold a piece of board on top of the spring to prevent it from popping up on you. Once you get it wound up tight enough to fit in the housing clamp a pair of vice grips on the spring to hold it together. Using the vice grips, place the spring in the housing making sure the outer hook connects with the housing. Slowly release the vice grips and the tough part is over. Now just reassemble the rope housing and done.
I was just going to say the same thing, look for my thread on my formula mx a couple years ago, did a nice write up on it.

Also used a couple bread ties, once I had it coiled on the board to hold it together, then once installed took them off...

If you follow the How to section you will have it done in 5 mins or less..
 

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Winding the spring is easy..... Thought it was self evident. Never mind the nail and vise grips you are just asking to get a spring across the face using that method. The correct way to do it is to wrap the spring back into the pocket in the recoil housing , outside to inside. Hook the spring into the outside notch in the recoil spring pocket and then just keep wrapping it in toward the center. The spring will naturally want to spring outward and this will keep it tight in the pocket and it won't want to come out as you wrap it. This is how the dealer does it and it is also laid out this way in the manual.
 
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