Guide for How to Rewind Polaris Cogs

Installed on older Polaris snowmobiles as the primary starting mechanism, and on many newer machines as a backup system, pull starters are designed to turn the engine over by hand. Also known as recoil starters, pull starters function by pulling on a cord wrapped around a spindle; the spindle turns a spring-loaded cog that spins the engine flywheel. If the springs slip off the cog, the system must be dissembled to reset the spring.

Instructions

1

Remove the pull-starter casing with the Phillips screwdriver. Unwind the starter cord from the spindle spool with your hand.

2

Insert the long-blade screwdriver as far as possible into the hole on the side of the spindle, locking the spindle in place. Loosen the retaining nut on the top of the spindle with the wrench and remove the screwdriver. Pull the spindle free from the cog with your hand.

3

Push the spring-loaded lever on the side of the cog away from the cog teeth with the blade of the flat-head screwdriver. Rotate the cog counterclockwise with your hand as far as possible.

4

Slide the spindle back over the cog with your free hand. Replace the retaining nut on the spindle and twist the nut hand-tight.

5

Pull the starter rope taught and remove the screwdriver to release the tension on the spring, reengaging the lever. Slowly release pressure on the rope until the rope is wound on the spindle.

6

Reinsert the long-blade screwdriver back into the hole on the side of the spindle. Tighten the spindle retaining nut with the wrench. Remove the screwdriver from the hole in the spindle and replace the starter casing, using the screwdriver.