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Old 12-25-2011, 07:27 PM   #1
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broken pull start rope repair??

So I yanked on the rope to start my sled this afternoon and the rope broke on my 98 ZL 500. The recoil works fine, just the rope broke about 3' from the handle. Any tips or pointers? I don't have a manual and will be ordering a new pull rope soon. I might even replace the rope on my 97 ZR 580 while I'm at it. I'm sure they are both original and will be heading up the the UP of Michigan in 2 weeks. Thanks.
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Old 12-25-2011, 08:16 PM   #2
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There is several threads on this, you can find them by using the search function. Here is just one RECOIL ROPE
They are a piece of cake to do nothing hard about it. Do the following and you won't have any problems. Remove the can should be 5 springs, then there are 3-10mm bolts I believe may be 11mm not sure, but anyway take them out of the recoil housing and remove that from the sled and set it to the side, once you have the recoil loose from the housing pull the rope all the way out and grip the white plastic wheel inside the recoil tight DO NOT LET GO.... now you can cut your recoil handle off ( the rope ) remember DO NO LET GO.... after doing this you can remove the old rope and insert the new in the recoil once you have a knot in the rope feed it back through your dash and put your handle back on then its safe to let go slowly and it will rewind its self to the proper tension and you can move it around to put the recoil back on just watch the wiring harness so you do not pinch the wires. I have done this many of time and its easy once you do it. Sometimes if you do not have a extra set of hands to hold the recoil I have already used the jaw vise grips with just enough force to hold it in place. If you have to pull the recoil housing and take the rope out, then you will have to put new tension on the spring by twisting everything counter clockwise (I think) and then install a new rope while holding everything. Its not as bad as it sounds. What sled are you doing this to the one in your profile? If so the ZL isn't hard. I've done mine before. But it will make it easier if theres two people once you have the tension back on it or you can use a larger pair of pliers to hold the cone in place just don't crack it. It may take you a coulp of times to get the tension right but its not bad. Hope this helps.
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Old 12-25-2011, 08:23 PM   #3
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I can handle that. Will do exactly as you stated. Ordered 2 new ropes and new Green handle. Hopefully they'll be here by Friday. Thanks!!
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Old 12-25-2011, 08:28 PM   #4
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Chevydog just replace the hole starter there cheap an easy change buy one off eBay and buy one for cheap
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Old 12-25-2011, 08:38 PM   #5
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I didn't see any new starter recoil assy. on ebay. Saw some used ones with used ropes. I just ordered 2 new ropes from Leaders Marine in Kalamazoo for $30 shipped. I'll check again. Thanks for info.
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Old 12-25-2011, 08:43 PM   #6
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I bought used for my zr witch I just went and got from my buddies cabin in harrison and brought to my uncles in Indian river I havent rode or seen it in two years an it still works fine lol
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Old 12-25-2011, 08:50 PM   #7
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DADSZR I was searching the ZR/ZL/ZRT section that's why I didn't come across your previous post. thx.
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Old 12-26-2011, 06:11 PM   #8
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Fixed it!! Piece of cake. Didn't even need to remove exhaust. Took about 10 minutes. Went to TSC and bought 15' of nylon rope and replace pull cord on both of my sleds, since I'm sure they were original. Thanks!!
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Old 12-26-2011, 09:07 PM   #9
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You should replace with somerhing other than plain nylon rope. I use spectra climbing rope. much stronger and you never have to do it again.
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Old 12-27-2011, 12:21 AM   #10
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What diameter 109?
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