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Polaris: EDGE 2002-2005, all models in the Edge chassis
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Old 01-15-2018, 04:32 PM
audaveh audaveh is offline
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Default Edge Recoil Rope Replacement

So the pull start rope broke on my 2003 RMK 700. How do I replace and tension the new rope without removing the recoil spring? Can't seem to find a YouTube video that addresses the edge chassis.
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Old 01-15-2018, 06:33 PM
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Here is the procedure outlined in the service manual.
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File Type: pdf Polaris 2003 recoil disassembly.pdf (47.4 KB, 49 views)
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Old 01-15-2018, 07:20 PM
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I have that, but I understand there is a way to change it without messing with the recoil spring.
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Old 02-02-2018, 12:37 PM
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spin the recoil in the opposite direction of the pull when starting the sled. coil it up pretty tight put a deep well socket or something between the recoil rope detente/rope hole and the case to keep it from spinning back. If you get the right length you will have the detente/rope hole lined up with the case hole. tie a not on the end of your rope. feed it through the rope hole in the plastic piece and out the hole in the case. Pull the rope all the way til the knot seats in the plastic. Put a Knot on the handle end. Hold onto the rope and take the socket out, the recoil will fill itself.
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Old 02-08-2018, 12:57 AM
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1. let the rope pull back into the housing until their is no tension on the spring.
2. remove the nut in the center of the center white disk and then the disk itself
3. note location of arm and small spring, and remove both
4. with no tension in hidden large spring carefully lift up spool containing rope
5. keep hidden large recoil spring flat in it's containment area
6. using 24" of duct tape, wrap 1 end around tip of rope to get a tension grip, and fold duct tape over itself to make it a 20" long flat x 1/2" wide tape with no sticky sides exposed
7. wrap rope and duct tape tightly into spool
8. insert end of duct tape through exit hole in housing
9. by keeping rope and duct tape tight, carefully place disk down on large hidden spring so that the bottom open groove in the spool are directly aligned with the bent tip of the hidden spring
10. reinstall small spring and arm, and center round disk
11. reinstall keeper nut
12. pull duct tape out of exit hole until rope is exposed
13. temporarily tie knot in end of rope
14. remove tape
15. carefully undo knot and thread behind water hose and up through center pull rope handle hole
16. insert rope tip in handle and tie double half hitch knot that loops twice inside of the tightening loop. Study the stock Polaris knot that you cut off the rope, and duplicate it. It is not two separate half hitches.
17. reinstall pull rope housing

Last edited by whoisthatguy; 02-26-2018 at 09:11 PM.
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Old 02-08-2018, 01:04 AM
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Quote:
Originally Posted by retiredpop View Post
Here is the procedure outlined in the service manual.
This method does not apply enough tension in the recoil spring, to pull the handle back into it's keeper slot. The temporary duct tape extension described above is required to get enough tension in the recoil spring.
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