I bought a new recoil spring and plastic reel (not sure what its call). After installing it and before reinstalling the cover I realized it's not smooth. It hangs up. Things I've checked: spinning the proper direction, the reel isn't making contact with housing, lots and little spring pressure, and little bushing is installed. I'm mechanically inclined so it's not like this is my first rodeo. For something so easy I can't figure out why it's not working properly. Do you guys have any ideas?

 

When you installed the spring,then the plastic reel(with the rope through the recoil hole,secured to the reel) you turn the reel enough to slip the rope into the reel cut out notch.Prewind the reel about 6 turns more,then slowly let it back up until the notch lines up with the hole,pull the rope out of the notch and let the reel rewind pulling the rope in. Rope handle should be tight against the nipple. When you pull the rope handle the ratchet should kick out quickly. Make sure you have a good film of grease around the inner side of the retainer plate and yoke so the reel can operate smoothly without sticking.

 

Did you buy the parts at your dealer? I always had problems with recoils rewinding and rope/spring installs.
Last time I just brought the pull rope recoil into the dealership and the dealer installed the new spring and rope for $10/labor in about 15 minutes while I browsed at new ATVs, then just took it home and bolted it back on.