The pull start on your Polaris four wheeler is the only way to start the engine, so if it is broken you must replace it. The cord you pull is connected to a turn wheel behind a metal cover that the cord comes out of. The cord is connected to the turn wheel by a metal nut on the end of the cord. The nut size on the cord will be different between models, but the replacement process is basically the same for all the Polaris models.
Things You'll Need
- Phillips screwdriver
- Box wrench
- Replacement cord
Park the Polaris ATV on level ground in an area with plenty of light. Allow the engine to cool if it is warm so that you don't burn yourself.
Remove the four Phillips head screws from the corners of the metal cover that the cord is coming out of using the screwdriver. Pull the metal cover off the engine. Unwrap the cord from around the turn wheel completely.
Spin the turn wheel using your hand until the nut securing the cord is at the top of the wheel facing you. Grab the metal stem on the cord with the pliers. Loosen and remove the nut using the box wrench. Hold the stem to keep the cord from turning as you loosen the nut.
Pull the cord off the turn wheel and through the hole on the metal cover. Keep the nut just in case the new cord did not come with one. Insert the metal stem on the new cord into the hole on the metal cover. Insert the stem into the hole on the turn wheel.
Tighten the nut onto the stem the opposite way than you removed it. Spin the turn wheel counterclockwise until you hear the spring lock into place. Wrap the new cord around the turn wheel. Make sure that the cord does not overlap itself. Replace the metal cover to the engine. Replace and tighten the screws to secure the cover to your Polaris's engine.
- "Polaris ATV 250 500cc, '85'97 (Owners Workshop Manual)"; Chilton; 1999
- "ATVs: Everything You Need to Know (Everything You Need to Know)"; Steve Casper; 2006
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