Starter cord pulled out of the housing, it

Assembling a recoil system on a Polaris 400 Xplorer involves several steps. While I can't provide an actual diagram here, I can outline the general steps involved in assembling a recoil system:

1. Preparation: Ensure you have all the necessary parts for the recoil assembly including the recoil starter, recoil housing, recoil spring, and any other associated parts.
2. Mounting the Recoil Housing: Begin by mounting the recoil housing onto the engine. It typically bolts onto the engine casing.
3. Inserting the Recoil Starter: Place the recoil starter mechanism into the recoil housing. It usually fits into grooves or mounts within the housing.
4. Attaching the Recoil Spring: Connect one end of the recoil spring to the recoil starter mechanism and the other end to a fixed point within the recoil housing. This provides the tension necessary for the recoil starter to function properly.
5. Installing the Pull Cord: Thread the pull cord through the hole in the recoil starter mechanism and tie a knot at the end to secure it. Wind the pull cord around the recoil starter as per the manufacturer's instructions.
6. Testing: Before completely sealing the recoil housing, give the recoil starter a few pulls to ensure it functions smoothly and retracts properly.
7. Final Assembly: Once you're satisfied with the recoil assembly, bolt down any remaining covers or components to secure the recoil system in place.

Always consult the specific service manual for your Polaris 400 Xplorer for detailed instructions and diagrams tailored to your exact model. Additionally, if you're unsure about any step, it's best to seek assistance from a professional mechanic or someone experienced with small engine repair.

If you are going to be repairing B&S air cooled engines, may I suggest that you make a handy tool for repairing the pull cord starter. To access the pull cord assembly, remove the blower housing to expose the backside of the pull starter. All of the B&S pull start engines have a starter clutch that secures the flywheel to the crankshaft. These clutches go bad after a while. Go to a local repair shop and ask if you can have an old B&S starter clutch. Take it apart and keep the spindle. Have someone weld a T bar handle to the spindle. You will use this to reload the spring in the recoil starter, winding backwards to load the spring. Use a C clamp to hold it in place after loading the spring. Insert the new nylon pull rope through the grommet and out through the hole in the rope spool. Tie a figure 8 knot in the end of the new rope. Slowly release the C clamp to allow the spool to rewind, loading itself with new pull cord. You need about +/- 20 inches of pull cord. Replace the rubber handle on the pull cord and you are ready to mount to blower housing back on the engine. I hope this helps. PS. See the attached url for the Operator's Manual for the 9000 horizontal. http://www.tranzsporter.com/tpdf/Briggs%20&%20Stratton%209000.pdf

First remove the pull starter housing.
The next part is tricky. You'll have to release and unwind the spring that rewinds the pull starter cord. Remember how you do this because after replacing the cord, you'll have to rewind the cord and spring before inserting it back in the housing.
re-attach the pull cord housing to the chain saw.
Hope this helps.

You have to remove the motor cover that the starter housing is riveted to. Usually three or four bolts around the perimiter of the housing and it will slide off with the starter housing.

Remove the four screws securing the starter houseing, with the starter removed, pull the cord out, tuck the cord into the cut a way in the side of the pulley and allow the cord to wind in slowley to let the tention off the spring, make sure all the tention has gone, now remove the centre screw, take away the pulley centre and the round spring from behind, note the hole in the pulley and the centre hub for the spring location, now carefully remove the pulley, be aware there is a large spring behind, remove the knot in the end and remove the starter handle, fit the cord back into the new pulley, refit the pulley into the cover making sure to locate into the spring behind, thread the cord back through the cover and reconnect the handle, knot the cord, re fit the round spring back into the locating hole in the pulley, re fit the pulley hub making sure the spring fits into the hole in the hub, re fit the securing screw, now put the cord back into the cut a way in the side of the pulley, wind up the spring, allow it to pull the cord back into the starter, only wind it enough to pull the cord fully back into the cover, re fit the starter.

Hi Baz, i will tell you a generic way of doing this as i don't know the model of your strimmer.
on the pull cord housing you will have 3 or 4 screws to secure the housing to the motor body, undo these. the housing will lift away from the main motor body, underneath this cover you will see a spring canister, there may be a screw or clip keeping this in place or some are just secured with the outcover. remove this canister you should see a coil spring in the middle and a groove around the outside where the cord goes. you should see a knot inside the cord grove where the cord is threaded through to secure, remove thisand remove old cord. Now the trickky bit! some times it helps to have a helping had, you will need to turn the coil spring so it tights up to its full tightness, then thread the new cord into the secureing hole where the old cord was located, then when you release the spring this will coil the cord round the cord groove. replace the pull handle on the end of the cord so there is no slack and replace on to motor in reverse order. Hope this helps.

I am assuming you are refering to the Starter cord. All the plastic pieces must be removed. Then the blower housing . Inside you will see the starter wheel that winds the cord. You must wind the wheel until it is not possible to wind anymore,dont force it.Secure the wheel by passing a screwdriver thru the wheel and thru the housing. Position the hole in the wheel with the hole in the blower housing where the cord comes in.Pass the cord thru both holes and knot the end inside the wheel. Use a lighter to melt the cord just a little so it will not come unknoted. Pull the screwdriver from the housing and slowley let the spring re-wind the cord.If its a 5 or 6 hp briggs it take about 88 inches of new cord.Hope this helps.

Remove the housing and pull the cord partly out. Then rewind the rest. Check to see if it retracts properly. Good Luck!

A new spring comes wound tight enough to be dropped into place in the starter housing (Easiest).

I invert and secure the starter housing and rewind the spring large coil to small (need eye protection, both hands and no women around work area!). I'm right handed so I tension the spring enough to insert it inside the previous coil while holding what has already been installed with my left about 180° from my right hand. The tension will hold the spring in the housing once completely inserted. Then bend slightly the inner most part to engage the starter spool. It will require about 2 turns of pretension to retract properly.
If you're lucky you can pull the cord out enough for a pretension then slightly raise and add the withdrawn cord to the spool.

Both methods require about 2 turns of pretension to rewind the cord when pulled.
Lou

you have to remove the starter housing, inside will be 2 knobs that spring out when the cord is pulled that contact the flywheel cap of the motor and rotates the crank. check if they are missing or damaged and that they ejecting when the cord is pulled. if not; replace.