Snowmobile Arctic Cat (2002 year). Manual - part 49

3-19

3

GR121D

2. Install the reel assembly with rope wound in the

appropriate direction.

GR507D

GR111D

3. Install the springs and ratchets.

GR506D

GR505D

4. Install the plate and secure it with the screw.

GR503D

GR502D

! WARNING

Exercise extreme caution when installing as the
spring may disengage and cause severe injury.

3-20

5. Route the recoil rope through the rope guide of the

recoil housing and through the recoil handle; then

tie a knot in the rope.

GR501D

6. Wind the rope counterclockwise 3-4 turns around

the roller.

7. Secure the recoil starter to the engine shroud.

GR304D

„

NOTE: At this point, install the engine (see Sec-

tion 2).

Recoil Starter 

REMOVING

1. Tie a slip-knot in the starter rope below the

console and allow the rope to slowly retract

against the starter case.

2. Remove the knot at the handle, remove the handle,

and account for the handle cap; then thread the

rope through the bushing in the console.

3. Remove the cap screws securing the starter

assembly to the magneto case; then remove the

starter assembly.

DISASSEMBLING

1. Secure the recoil starter in a vise.

2. Rotate the roller counterclockwise until the notch

of the roller is near the rope guide in the case.

Guide the rope into the notch and slowly allow the

roller to retract until all recoil spring tension is

released.

B522

3. While exerting downward pressure on the friction

plate, remove the nut and washer or cap screw.

B523

4. Slowly release the plate and lift the plate with

friction spring free of the recoil roller.

5. Remove the friction spring from the plate.

! WARNING

Always wear safety glasses when servicing the
recoil starter.

! WARNING

During the disassembly procedure, continuous
downward pressure must be exerted on the reel so
it does not accidentally disengage and cause injury.

! WARNING

Care must be taken when allowing the recoil roller
to unwind. Make sure all spring tension is released
before continuing.

3-21

3

B524

6. Remove the pawl; then remove the return spring.

B525

7. Carefully lift the roller free of the case making

sure the main spring does not accidentally

disengage from the case.

8. Remove the main spring from the case by lifting

the spring end up and out. Hold the remainder of

the spring with thumbs and alternately release

each thumb to allow the spring to gradually release

from the case.

„

NOTE: Do not remove the main spring unless

replacement is necessary. It should be visually
inspected in place to save time.

9. Unwind the rope from the roller, untie the slip-

knot, and remove the rope.

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Clean all recoil starter components.

2. Inspect all springs, washers, and pawl for wear or

damage.

3. Inspect the roller and case for cracks or damage.

4. Inspect the center hub for wear, cracks, or damage.

5. Inspect the rope for breaks or fraying.

6. Inspect the main spring for cracks, crystallization,

or abnormal bends.

7. Inspect the handle for damage, cracks, or

deterioration.

ASSEMBLING

732-515A

1. Hook the end of the main spring around the

mounting lug in the case.

2. Insert the main spring into the case; then wind it in

a counterclockwise direction until the complete

spring is installed.

„

NOTE: The main spring must seat evenly in the

recoil case.

3. Insert the rope through the hole in the roller and tie

a knot in the end; then wrap the rope

counterclockwise around the roller leaving

approximately 50 cm (20 in.) of rope free of the

roller.

4. Apply low-temperature grease to the main spring

and hub.

5. Align the hook in the end of the main spring with

the notch in the roller.

! WARNING

Care must be taken when lifting the roller free of the
case.

KEY

1. Starter Assy
2. Starter Roller
3. Main Spring
4. Ratchet Set
5. Friction Spring
6. Washer
7. Return Spring
8. Friction Plate

9. Nut

10. Starter Rope
11. Cap Screw
12. Starter Pulley
13. Bolt
14. Decal
15. Pawl

3-22

6. Carefully slide the roller over the hub and engage

the spring with the roller.

7. Install the return spring making sure the end is

properly installed in the hole in the roller; then

install the pawl making sure the return spring is

properly preloaded.

B525

8. Slide the end of the rope through the rope guide of

the case; then tie a slip-knot in the rope.

9. Place the friction spring into position on the

friction plate making sure the head of the spring is

opposite the flat of the inner hole. Apply a low-

temperature grease to the plate.

B524

10. Place the plate into position making sure the flat of

the inner hole is correctly positioned in the hub.

Apply blue Loctite #242 to the threads; then

secure the drive plate with a washer and nut or

with a cap screw. Tighten the nut to 1 kg-m

(7 ft-lb) or tighten the cap screw to 0.8-2.1 kg-m

(6-9 ft-lb).

B526

11. With 50 cm (20 in.) of rope exposed, hook the

rope in the notch of the roller.

12. Rotate the roller four or five turns counter-

clockwise; then release the rope from the notch

and allow the rope to retract.

13. Pull the rope out two or three times to check for

correct tension.

„

NOTE: Increasing the rotations in step 12 will

increase spring tension.

INSTALLING

1. Place the starter assembly into position against the

magneto case.

2. Secure the starter with cap screws. Tighten to

0.7 kg-m (5 ft-lb) on the triple models, to 1 kg-m

(7 ft-lb) on the L/C twin models, or to 1.1 kg-m (8

ft-lb) on the F/C models.

„

NOTE: Before tightening the cap screws, slowly

pull the recoil rope until the pawl engages; then
tighten the cap screws. This will center the recoil
against the magneto case.

3. Thread the rope through the bushing in the

console; then install the handle and secure with a

knot. Seat the cap.

4. Release the slip-knot in the rope.