05 rev recoil

[kellyandhislimo]

Ok I can't figure this out and i need some help with it. My recoil won't catch very good when I go to start my sled. When it is cold (first start of the day) I can get it to catch a little and get short strokes out of it. When I get it started and run for awhile and stop for a beer, I mean hot choclate, it will start perfect the rest of the day. I pulled the recoil off and cleaned it up real good and everything is there, nothing is broke and nothing seems to have excessive wear. BRP is telling me I need to put new plastic peices in it but thats $75 for two little pieces that look brand new. what could it be and how can I fix it? any help is welcome forsure.

 

[tex78]

well mine did that and then i was screwed one day when i went to start it and all the stuff plied up.... left me not able to run it... and didn't have any tools to take it off and use the rope on the clutch.... it was 270.00 from doo for the hole thing as an asmb......... if i could have found a electric starter kit at that time i would have done that for the extra 230.00.....

 

[DRD]

The recoils are not know for their stellar design. The heat from the can doesn't help either. Maybe add some heat tape to the cover.
Cheaper kits:

A complete new recoil out of the US is around $170.(Felkers)
I've heard the recoil from an RT fits and is Aluminum instead of plastic.
If you had it apart make sure the clip that holds the mess together is secure. If it comes apart it makes a mess and can take out the stator etc. Some guys actually drill the center post out and install a bolt/washer to keep this from happening.

 

[kellyandhislimo]

I am just trying to figure out what is worn down. All the parts in mine look like they are in mint shape, they look new, and I don't understand what is not making it catch. I have had it off three or four times to see what is going on but when I have it off it seems to function fine, put it on and it won't catch. once the sled is warmed up it catches right away everytime. I have never had a recoil do this before.

 

[DRD]

Make sure nothing is warped and then relaxing once it's warm?? I don't put any lubricant on the plastic stuff either, sometimes makes them sticky when it's cold.

 

[boots]

maybe take apart and clean out the grease on the top parts and put dry graphite and make sure you replace the push nut

 

[Summitric]

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Tag Description Req Price
1 Loading... SKU: 420810867
Connecting Flange 1 $44.27
2 SKU: 420241236
Socket Screw M6 X 16 1 $1.44
3 Loading... SKU: 420889765
Rewind Starter INCLUDES ITEMS 3 TO 13 1 $129.95
4 Loading... SKU: 420811403
Starter Housing 1 $46.19
5 SKU: 420939115
Rewind Spring 1 $16.93
6 SKU: 420852288
Rope Sheave 1 $21.94
7 SKU: 412500200
Starter Rope 1 $2.90
8 Loading... SKU: 420852297
Pawl 1 $13.47
9 Loading... SKU: 420852307
Pawl Lock 1 $8.46
10 Loading... SKU: 420847925
Stage Sleeve 1 $6.54
11 SKU: 420250400
O-Ring 1 $2.07
12 SKU: 420852520
Lock Ring 1 $4.76
13 SKU: 420845560
Locking Element 1 $1.33
14 SKU: 420941256
Hex Collar Screw M6X30 4 $1.20
15 SKU: 420899763
Molykote Pg 54, 10 G 1 $16.16

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[Slamnek]

Just replace it. its not nice when they let go and little pieces fly into your stator. That happened to my brothers 02 ZX 800 but it was just the retainer clip that went into the stator. We got it out and the stator lasted the rest of the winter untill we went to load it on a trailer cuz we were leaving for mcbride in the morning and as the sled was warming up it just shut off. New stator and all was good.

 

[kellyandhislimo]

maybe take apart and clean out the grease on the top parts and put dry graphite and make sure you replace the push nut

I did this minus the dry graphite. I had it clean enough to eat off of and it didn't make a difference.

 

[nielsy]

when the retainer clip is loose the pawl will not come out and engage

 

[SaskSummit]

Had the same issue on my 06. All you have to do is push that goofy liitle star washer on tighter. Seems stupid but that all it takes. It is the little sucker that holds everything on. I changed a bunch of crap as well and nothing worked. Let me knoe how you make out.

 

[Trashy]

$228.46 later..... I just replaced the whole thing.
You can only rebuild plastic to a certain point!

 

[ski-doober]

I solved this problem on both our sleds with the o-ring replacement and i had to get them from doo as they are a weird size
3 $ for it and i also bought the retainer clip on the second one and cut the old one off was way easier than trying to get it off

 

[glengine]

I never stock the ones that are made for the 800, i always bring in the ones for the 1000 because you are correct the pawl is aluminum instead of that plastic crappy pawl. They work great last alot longer and they are only 200.00 here.