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I have to replace the pull cord guide on my 92 Polaris XCR every 40 or so pulls. The cheap plastic really wears down quick. Its not like the metal spring like device used on most Polaris sleds, I belive polaris only used them on Twins with liquid cooled hydraulic disc brakes. its a pain in the a** cause I have to take everything apart to switch it. Any one have any ideas

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Has the rope ever been replaced, maybe its too rough. you might be able to wax the cord. You could always drill a hole and put the metal spring piece on the sled.

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I have the same problem. Take a look at the 2000 500 XC SP. They have a real nice brass tube that bolts right on top of the brake assembly. It works really well.
 
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