1995 Polaris 425 Pull Rope Repair/Replacement - ATVConnection.com ATV Enthusiast Community

jhuff1 · #1 (**permalink**) 05-21-2008, 11:14 AM

The pull rope on my 425 will not retract. Anyone know the best way to fix it? (Other than take it to the Dealer)

TLC · #2 (**permalink**) 05-21-2008, 11:50 AM

Take the recoil off and see what it is, it may just be the spring. The most expensive part is the plastic reel for $60. Once the recoil is off just bring it to the dealer with you and they will sell you the required part and put it together in 10 minutes for $13 labor.at least mine did.

I know how to put recoils together but for $13 I just let a person how does it day after day do it,its quicker.

jhuff1 · #3 (**permalink**) 05-21-2008, 01:13 PM

I am concerned with taking off the housing on the side of the engine with the pull start. It appears that the cover has a oil plug in the bottom. Is that right?

94harley · #4 (**permalink**) 05-21-2008, 04:54 PM

<div class="FTQUOTE"><begin quote>Originally posted by: jhuff1

I am concerned with taking off the housing on the side of the engine with the pull start. It appears that the cover has a oil plug in the bottom. Is that right?</end quote></div>

It has a drain plug but there should NOT be oil in the recoil housing.

TLC · #5 (**permalink**) 05-21-2008, 05:09 PM

Just take the recoil off by removing the number of small 10mm bolts,there are no surprises in there except the bendix drive will be loose,thats all. The bottom plug is to drain water if it gets by the rope hole and the top plug is a quick place to check timing marks.

jhuff1 · #6 (**permalink**) 05-21-2008, 06:34 PM

Thanks. That explains the rust on the rope. It has never been drained (13years).

shelby4 · #7 (**permalink**) 05-26-2008, 11:45 PM

I have a recoil problem, I have drained the water out and tried working the pull rope in and out but pushing rope in is useless.... What lubricant do you suggest to put in the recoil housing to free things up?

jhuff1 · #8 (**permalink**) 05-27-2008, 08:41 AM

Sounds like the spring is broken. I took the cover off of mine this weekend and the spring was broken in 2 or 3 places. I rarely used the rope in the 13-yrs. I have had the ATV. It was very rusty.

TLC · #9 (**permalink**) 05-27-2008, 11:36 AM

You must make sure the pull handle is seated tight ,its the only way water gets in the recoil. Once water gets in there is submerges your $300+ Stator, pulse coil,bendix drive and rust the flywheel. Since I rarely use the pull rope I have the handle siliconed on the housing rope hole.

CaptainQuint · #10 (**permalink**) 05-28-2008, 02:14 AM

<div class="FTQUOTE"><begin quote>Originally posted by: TLC Since I rarely use the pull rope I have the handle siliconed on the housing rope hole.</end quote></div>

Dang. That's a good idea. I'm gonna do that first thing tomorrow. Thanks!