Anybody have any insight on what could be causing oil to get into my recoil starter on a 1997 polaris xplorer 500 ? When you pull the rope out it is saturated with oil.

 

Is your oil level dropping? If not, its just the rope is wet and looks to be oily, water and junk gets into the recoil housing though the pull rope hole because the handles is suppose to act like a plug for the rope hole but it does a bad job at it in most cases.

Take the recoil housing off and clean the inside good (Brake cleaner spray works well), used silicone gasket when reinstalling the cover and also silcone the rope handle over the rope hole and water will not get in again.

 

I can't say that I've noticed the level dropping, I changed the oil last night and it was full so I'll check it again. I'm 100% it is oil that's on the rope and not water. I guess I'll pop the cover off and look around.

 

The Bendix drive in there is a oily part and the dirty water will pick that up and transfer it to the rope. I would relube the Bendix also before putting the cover back on.

 

Thanks for the advice!

 

<div class="FTQUOTE"><begin quote>Originally posted by: mtlion

Anybody have any insight on what could be causing oil to get into my recoil starter on a 1997 polaris xplorer 500 ? When you pull the rope out it is saturated with oil.</end quote></div>

If oil saturated on recoil rope then possibly seal in stator plate or o-ring behind stator plate leaking into stator,flywheel and recoil area. You might want to check out before any damage to stator happens.

 

Thanks. How hard is it to get to those seals? Is the stator/flywheel area right behind the recoil starter? I am no master mechanic but I am learning. Any special tools I might need?

 

<div class="FTQUOTE"><begin quote>Originally posted by: mtlion

Thanks. How hard is it to get to those seals? Is the stator/flywheel area right behind the recoil starter? I am no master mechanic but I am learning. Any special tools I might need?</end quote></div>

Seal inside stator,have to pull flywheel to get to. Also o-ring is around back of stator plate(usually the source of leaking)

 

Mtlion - Not sure if you are still following this thread, but was wondering what your outcome was? I have the same problem on a 2002 Polaris sportsman 500. Battery dead so went to pull start & got a nice line of oil drops right up my pants, shirt & mouth & face. At least it tasted like a bit of oil. Did you have to pull engine & split the cases to change the seal? Thanks & hope it was an easy fix for you!