Service Manual

Repair Recoil Starter
The most likely components on the recoil
starter to require repair are the coil spring and
starter rope.
‘A
CAUTION: Wear safety
glasses and use extreme care
when working with the recoil spring. If
the spring
is suddenly released, injury
could result.
Rope Replacement
1. Rope replacement may be accomplished
without disassembly of the starter. First take
the starter off the engine.
2.
If the pulley spring has not be detensioned,
withdraw about one foot of rope and while
holding the pulley in place, unwind the
remaining rope on the pulley.
3. Slowly release the rope until the pulley
spring fully relaxes. IMPORTANT.
Do not
turn the pulley any further in the clockwise
direction or the spring will unhook from the
center hub.
If thespring un-hooks the pulley
will turn freely in the counter-clockwise
direction without an increase in spring
tension. To correct, the pulley must be
removed and the spring re-hooked.
4. Untie the knot in the rope and replace with
new. The rope is 4mm (5/32 in.) in diameter
and 175cm (70 in.) long.
5. Wrap the new rope around the pulley in a
counter-clockwise direction. See Fig.
3-36.
6. When the rope is fully wound on the pulley,
extend about two feet of rope, hold the
pulley in place and take two additional
wraps of rope around the pulley in a
counter-clockwise direction. This will pre-
load the spring.
7. Re-install the recoil starter.
Spring Replacement
1. Follow steps one through nine under
“Recoil Starter Removal and Disassembly”
on page
19.
2. Carefully remove the broken spring to
prevent rapid expansion of the spring.
CAUTION: Wear safety glasses and use
extreme care to prevent injury.
3. The replacement spring is provided with a
wire retainer to hold it together.
4. Place the spring in the pulley and release
it
from its retainer.
5. The spring should be installed in the pulley
as shown in Fig. 3-37.
6. If the spring has expanded outside the
pulley, it can be reinstalled by first placing
the hook end into the pulley. See Fig. 3-37.
7. Wind the spring into the pulley in a counter-
clockwise direction from the outside until
the spring is fully retained.
8. Place the pulley in the recoil housing and
turn it slowly in a counter-clockwise direc-
tion, with a slight down pressure, until the
pulley drops down indicating the spring is
hooked on the center hub.
Reassembly
1. Install the pawl-pivot pin. See Fig. 3-35.
2. Install the nylon washer, starter pawl and
spacer. See Figs. 3-34, 3-33.
3. Install the friction spring and pawl guide.
See Figs. 3-32, 3-31.
4. Install the friction disc and mounting nut.
Use a thread locker on the nut: e.g. Loctite
242. See Fig. 3-30.
5. Install the recoil rope. Refer to steps 5 & 6 of
Rope Replacement on page 21.
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