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Likely the recoil starter is kaput. Removing spark plug so there's no compression, then pull starter. If it's still hard pull, remove recoil starter assembly and spin engine by hand. If engine spins freely, replace recoil start.
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:
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.
Mounting the Recoil Housing: Begin by mounting the recoil housing onto the engine. It typically bolts onto the engine casing.
Inserting the Recoil Starter: Place the recoil starter mechanism into the recoil housing. It usually fits into grooves or mounts within the housing.
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.
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.
Testing: Before completely sealing the recoil housing, give the recoil starter a few pulls to ensure it functions smoothly and retracts properly.
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.
? 2:52
https://www.youtube.com/watch?v=J0KJuqsJJ_k
Feb 16, 2012 - Uploaded by Champion Power Equipment
How To: Rewind a Recoil Rope (Fix a Broken Recoil Rope) .... Back off until rope hole in pulley lines up ...
? 4:49
https://www.youtube.com/watch?v=tmo6oYOJJ4U
Jul 15, 2011 - Uploaded by eReplacementParts.com
How to Repair a Small Engine Recoil Starter ... Would like to now use the pull cord on the mower but it won ...
It appears that the recoil spring is broken or has come away from its anchor position. It means opening the unit (usually 4 screws) and re-seating the recoil spring and rewinding the recoil spring so that it will recoil the starter rope with the correct tension. It may take a few attempts to get it right. If you do get it right, don't over-extend the starter rope when starting the washer. Someone was over-zealous!
The recoil starter is damaged or tangled up inside. Some can be disassembled in made to work but if not a new recoil starter can be purchased. I hope this helps.
You may have to remove the recoil starter. Be careful, the spring, etc. may have disconnected from the recoil starter housing. There are probably 3 machine screws to remove to get the starter assembly off.
Then try the electric start.
Starter assemblies are a standard repair part.
Let me know if this helps.
Gary
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