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Old 03-07-2011, 04:34 PM
Jsleboda15's Avatar
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Recoil starter problem.....

I have a 1988 Polaris trail boss 4x4 250cc and one day about 1 yr ago i went to start it up with the pull starter and the rope stayed out and didnt coil back in. This week i thought i should get back into it so I started to take it apart and I took off the chain covers, the chain and the first cover that the rope is on but i took off all the bolts to the next part but it wont budge off.

Also the first time i took it apart i spun the wheel that the rope goes around on and it just spun and didnt catch onto anything so im guessing it could be the spring but i cant get the cover off so i cant figure it out.....please help lol

and do you think that it can still be started if i just take the rope off?

Last edited by Jsleboda15; 03-07-2011 at 04:40 PM.
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Old 03-07-2011, 07:24 PM
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Welcome to the board!
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Old 09-01-2011, 09:25 AM
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removing recoil starter.

I just had the same problem removing the recoil housing assembly from my 250 trail Blazer when I installed a new starter in it.

The factory uses some kind of silicone sealer and it can really make the housing stick to the engine case.

broman suggested that I soak it with WD-40 and this did the trick for me.
I was able to use a long prybar on the front of the housing and it popped right off. I tried hitting it with a rubber mallet, but that didn't work.

If that doesn't work you can try heating it and that might loosen the sealer.

Good luck.
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Old 09-01-2011, 10:40 AM
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If its spinning around and not catching it sounds like the spring is broke the spring comes pre wound from us that helps with the assembly of the recoil. We have recoil rebuild kits available from our online store Hit-The-Gas New and Used OEM Parts for Polaris, Yamaha, Suzuki, Kawasaki, ATV, Jet Ski, Motorcycle, Ranger, and Dirt Bike feel free to check it out. ~Aaron
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Old 10-24-2012, 08:31 AM
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so i just got back into fixing this atv, i took the housing off the the fly wheel. now i noticed that the peice that holds the ratchet, and the spring that engages with the fly wheel is broken. one of the tabs broke off...So i know that is one problem but as for the spring im guessing it is in that housing that i took off, but i dont know how to take it apart further. even to get at the guide and the ratchet that are broken. i took off the housing cover where the rope goes but i still dont understand how to take it apart. I looked at a schematic from bike bandit (ill put the link below) but i still dont understand how to take it apart. if someone could help out i would really appreciate it, thanks.


1988 Polaris 250 Trail Boss 4x4 W888127 Parts, 1988 Polaris 250 Trail Boss 4x4 W888127 OEM Parts - BikeBandit.com
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Old 10-24-2012, 08:33 AM
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ill probably put a couple of pictures of the housing up tomorrow or sometime soon
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Old 10-24-2012, 10:27 AM
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Sounds like the peice on the reel that holds the metal tab that swings out is broken. Quite common. You need to get a new one. Other parts should be okay though. when you get it appart you have to preload the spring. Easiest way to do it is to take off the handle and wind it up to preload. WHen you have it under tension, put the rope through the cover peice and reattach the handle.
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