the starter rope on my 1965 9.5 hp evinrude sportwin wont rewind. It rewinds maybe one or two turns, but to get it rewound enough to pull again I have to take the lid off and wind it manualy. Even then the I can only rewind it four turns or so before the tension of the spring starts reversing. Do I need to replace the whole starter assembly? is there a cheaper fix? Please help!
It sounds as though the starter has been incorrectly assembled or the spring has slipped and lost its pretension.
Provided the spring is not broken and nothing is damaged you need to remove the cord. Pretension the spring by the correct number of turns then refit the cord.
You can either get an assistant to prevent the pinion rising and engaging while you wind the spring, wind a stout elastic band around the top to prevent it rising or remove the plugs and allow it to engage and turn the flywheel.
Once tensioned a suitable sized drill bit, pin punch or small screwdriver through the roll pin will stop it unwinding again while you attach the cord.
The number of turns to pretension the spring I am not sure of.
Mine is only 12½ turns, yours is possibly 16½ turns. Whatever it needs to be just enough to recoil the cord but not so many that you risk breaking the spring when the cord is pulled to its limit