Pull Start Reel wont come off!!!!!

15239 Views 17 Replies 6 Participants Last post by latebird, Sep 8, 2021

JamATV

Discussion Starter · Jun 23, 2016

I have a Polaris Trailblazer 250 and we cannot for life of us get the reel off the pull start assembly!! It will not budge! Any tips or tricks would be great! :Flush:

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twostarrz

· #2 · Jun 23, 2016

You have to thump it with a rubber mallet and or I use wood chisel gingerly between recoil housing and engine case to break seal. If you wedge between use extreme caution.

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Mine - 2013 polaris sportsman 800. 28x9x12 and 28x11x12 ITP mega mayhems on 12x7 ITP black steel wagon wheels, 4500# venom winch, rear tool box.

Hers - 2008 Yamaha wolverine 450. 26x12x12 super grip super lites rear, 26x9x12 super grip super lites front, 1 1/2" spacers all the way around, pro mark 3000# winch on custom mount, HMF pipe, K&N air filter, jet kit, custom rear rack with seat/toolbox and 5 gallon gas can mount.

Daughter - 1999 polaris scrambler 500 4x4. 22x12x10 bear claws rear, 23x7x10 bear claws front, reinforced rear swing arm (long story), 4" lift kit in rear, 3000# promark winch on custom by me front bumper, rear cargo box.

Sons - 2000 polaris scrambler 400 4x4. 22x12x10 bear claws rear, 23x7x10 bear claws front, 4" lift kit in rear, rear cargo box
Sold:
2008 Yamaha wolverine 450
2004 Yamaha warrior 350
1999 Yamaha blaster 240 big bore
1995 kawasasaki Mojave 250
2001 Polaris sportsman 90
2008 kolpin 90
1985 Suzuki lt250R quadracer

JamATV

Discussion Starter · #3 · Jun 23, 2016

We have it off the engine already just cant seem to unthread the plastic reel to put in the new recoil spring.

twostarrz

· #4 · Jun 23, 2016

Sorry I misread. I always wind it up then thread new cord in from outside. I don't like to deal with the spring. Will that work?

Sent from my iPhone using Tapatalk

Mine - 2013 polaris sportsman 800. 28x9x12 and 28x11x12 ITP mega mayhems on 12x7 ITP black steel wagon wheels, 4500# venom winch, rear tool box.

Hers - 2008 Yamaha wolverine 450. 26x12x12 super grip super lites rear, 26x9x12 super grip super lites front, 1 1/2" spacers all the way around, pro mark 3000# winch on custom mount, HMF pipe, K&N air filter, jet kit, custom rear rack with seat/toolbox and 5 gallon gas can mount.

Daughter - 1999 polaris scrambler 500 4x4. 22x12x10 bear claws rear, 23x7x10 bear claws front, reinforced rear swing arm (long story), 4" lift kit in rear, 3000# promark winch on custom by me front bumper, rear cargo box.

Sons - 2000 polaris scrambler 400 4x4. 22x12x10 bear claws rear, 23x7x10 bear claws front, 4" lift kit in rear, rear cargo box
Sold:
2008 Yamaha wolverine 450
2004 Yamaha warrior 350
1999 Yamaha blaster 240 big bore
1995 kawasasaki Mojave 250
2001 Polaris sportsman 90
2008 kolpin 90
1985 Suzuki lt250R quadracer

JamATV

Discussion Starter · #5 · Jun 23, 2016 (Edited)

the recoil spring is broken and wont wind up, but thanks for helping!

twostarrz

· #6 · Jun 23, 2016

What year machine?

Sent from my iPhone using Tapatalk

Mine - 2013 polaris sportsman 800. 28x9x12 and 28x11x12 ITP mega mayhems on 12x7 ITP black steel wagon wheels, 4500# venom winch, rear tool box.

Hers - 2008 Yamaha wolverine 450. 26x12x12 super grip super lites rear, 26x9x12 super grip super lites front, 1 1/2" spacers all the way around, pro mark 3000# winch on custom mount, HMF pipe, K&N air filter, jet kit, custom rear rack with seat/toolbox and 5 gallon gas can mount.

Daughter - 1999 polaris scrambler 500 4x4. 22x12x10 bear claws rear, 23x7x10 bear claws front, reinforced rear swing arm (long story), 4" lift kit in rear, 3000# promark winch on custom by me front bumper, rear cargo box.

Sons - 2000 polaris scrambler 400 4x4. 22x12x10 bear claws rear, 23x7x10 bear claws front, 4" lift kit in rear, rear cargo box
Sold:
2008 Yamaha wolverine 450
2004 Yamaha warrior 350
1999 Yamaha blaster 240 big bore
1995 kawasasaki Mojave 250
2001 Polaris sportsman 90
2008 kolpin 90
1985 Suzuki lt250R quadracer

JamATV

Discussion Starter · #7 · Jun 23, 2016

Im not really sure haha, I'm thinking its a 1998-2000.

JamATV

Discussion Starter · #8 · Jun 24, 2016 (Edited)

2

Here is what it looks like on both sides, I'm trying to remove the reel... do I even need to remove that reel to replace the recoil spring? Im not too sure that I really do need to remove it now...?

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JamATV

Discussion Starter · #9 · Jun 24, 2016

I still cant get it off, any suggestions please help!

hatzie

· #10 · Jun 24, 2016

JamATV said:
Here is what it looks like on both sides, I'm trying to remove the reel... do I even need to remove that reel to replace the recoil spring? Im not too sure that I really do need to remove it now...?

Soak it with pb blaster and leave it overnight.

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twostarrz

· #11 · Jun 24, 2016 (Edited)

http://www.babbittsonline.com/oemparts/a/pol/5034f0a7f870022b94ea3035/recoil-starter-trail-blazer

It looks like the recoil spring is on the backside of the housing from the plastic rope reel. I agree soak it and let it sit. Come at it tomorrow with a clear head.

Sent from my iPhone using Tapatalk

Mine - 2013 polaris sportsman 800. 28x9x12 and 28x11x12 ITP mega mayhems on 12x7 ITP black steel wagon wheels, 4500# venom winch, rear tool box.

Hers - 2008 Yamaha wolverine 450. 26x12x12 super grip super lites rear, 26x9x12 super grip super lites front, 1 1/2" spacers all the way around, pro mark 3000# winch on custom mount, HMF pipe, K&N air filter, jet kit, custom rear rack with seat/toolbox and 5 gallon gas can mount.

Daughter - 1999 polaris scrambler 500 4x4. 22x12x10 bear claws rear, 23x7x10 bear claws front, reinforced rear swing arm (long story), 4" lift kit in rear, 3000# promark winch on custom by me front bumper, rear cargo box.

Sons - 2000 polaris scrambler 400 4x4. 22x12x10 bear claws rear, 23x7x10 bear claws front, 4" lift kit in rear, rear cargo box
Sold:
2008 Yamaha wolverine 450
2004 Yamaha warrior 350
1999 Yamaha blaster 240 big bore
1995 kawasasaki Mojave 250
2001 Polaris sportsman 90
2008 kolpin 90
1985 Suzuki lt250R quadracer

hatzie

· #12 · Jun 25, 2016 (Edited)

The guide looks like it's threaded into the reel.
You may have to sacrifice the plastic reel by heating the metal hub to get the guide shaft loose...
It looks like a reel 3083814, guide 3083913, hook-spring for the ratchet 3083924, and spiral reel take-up spring 3083815 are over 2/3 the price of a whole new unit 3083924.

If you get a new unit be sure to remove the reel from the guide shaft and coat the threads with never seize. If you manage to get yours apart I'd recommend the same on that one.

JamATV

Discussion Starter · #13 · Jun 28, 2016

Well I need a whole new one, Im gonna get a used one off Ebay. Something has broke off inside not allowing us to unthread the pulley so I have to get the whole new assembly. Thanks everyone

Jeff2001trailblazer

· #14 · Jul 5, 2021

JamATV said:
I have a Polaris Trailblazer 250 and we cannot for life of us get the reel off the pull start assembly!! It will not budge! Any tips or tricks would be great! :Flushk it's simple first lock your set of vise grips on the dog inside the housing then lock it tight in a vise the get a sledge hammer with a small chiesl and in the pull ring those open holes hit it counter clock wise really good she come free I promise a couple really good hits should do it

Jeff2001trailblazer

· #15 · Jul 5, 2021

Any questions you can call me 732-575-8249

latebird

· #16 · Jul 5, 2021

Jeff2001trailblazer said:
Any questions you can call me 732-575-8249

You are responding to a 5 year old thread - if he doesn't have it fixed by now he probably parted it out

Rico25

· #17 · Sep 8, 2021

I am having the exact same issue currently and I can’t get an answer anywhere

latebird

· #18 · Sep 8, 2021

2

Rico25 said:
I am having the exact same issue currently and I can’t get an answer anywhere

Have you tried looking in the service manual?

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