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I know what you mean. I rebuilt mine and made the same mistake! It wouldn't even pull over until I fixed it. After that it worked a few times then stoped all together. I'm going to order a brand new one and rebuild the original as an emergency back up for up at the cabin.

That make sense about the pawl not going all the way out and engaging the cup. I didn't clean everything very well in my excitement to get it all back together. Maybe some stuff is causing it to hang up. I'll take a closer look when I open it up again. I would put a new one in but I am up at...

The pull start on my '06 REV packed it in a while back and when I opened it up, the larger plastic wheel with the arm on it was broken. I replaced all the parts that looked worn or broken and put the pull start back on the sled. Now when I go and pull on the cord, it doesn't pull over the...

Thanks. It's hard to picture with my sled up at the cabin. I'll take a drill and unibit up with me though to make it easier.

Thanks for the clarification. How did you make sure the top holes were lined up with the screws. Did you just eye ball it?

I guess I should have read more closely the first time. So you drilled out two access holes for the top screws then. Were there any holes existing already that you just enlarged, or did you have add them?

How did you end up using the drill and unibit? I'm not getting it.

Thanks ;-)

The sled is up at our cabin so I'll need to take some tools with me to do the job. Does anyone know what size the bolts are that mount the pull start? Do I need to take a ratchet extension to get at those same bolts? Anything else I'll need to do this? Thanks, C.

Four of us who all work together are all lucky enough to own places up there, so we just stayed at our own houses in town. The mine shaft is a decent play to stay though. The pub has great food too!

I can't seem to find the right part number for the starter cup (the number above doesn't match up to the parts diagram). Do you have any more info on this or a link?

Yah, but then I would have more problems to worry about than just a faulty pull start! ;)

Thanks. I'll order those parts and fixer up.

So, check that the entire pull start is on tight and if that isn't the problem, then replace parts 7-12. Is that right guys?

The cord would go back in just as it normaly would, very easy. Does that point to anything specific being need of replacement?

I took my '06 REV 800 out for a couple of rides last week and early on, the pull start would not engage. It would just pull out all the way without pulling over the motor. After a couple of tries it started working again and I thought all was well. A couple of days later it did it again and...

Just back fom a week in Bralorne. Despite the lack if snow in town, sledding was actually pretty good outside of it. We found fresh powder at the far end of kingdom lake road. The Hurley (including east) was in great shape on all that we rode. The road out to the Noel was also really good and...

Dropped off a sled in town (Bralorne) today and there was about a foot and a half I town and it looked like much more in the hills. Heard other sleds riding up in the back country but didn't talk to anyone about the conditions up there. A group of us are heading up for a week starting this...

Thanks for the link. Looking pretty lean up there!

Cool! Thanks for the confirmation.