recoil rope replacement

I have a late 90's 20hp evinrude 2 stoke ss outboard that i pulled the cord out of. Scared to open up the recoil mechanism, flying springs and such. Cant find the model and serial, bought second hand from now out of business boatyard. Other then "go buy a manual" (on the to do list) any tips or step by steps? Thanks!

Re: recoil rope replacement

no advice?

Re: recoil rope replacement

two things you can do - one is look up a late 90s model motor of your size on shop2evenrude or marineengine dot com. Look at the recoil starter recoil and get an idea of the parts breakdown. Two is do an advanced search on this forum for the topic. You may have to try different words to search for (pull start, recoil, rope). Don't include your motor or HP. I am pretty sure Joe Reeves posted step by step procedure for repair on a "Top Mount Starter". Heck try that phrase even. Good luck!

Re: recoil rope replacement

this is joe reeves method quoted for an older 18 hp.


(Manual Starter Assembly)
(This pertains to the type of Manual Starter Housing that sits over top of the flywheel)
(J. Reeves)

Lay the manual starter housing upside down on the workbench.

Wind the spring "counter clockwise" in your hands so that you can lay it into the housing, having the outer spring end hooked over the retaining pin. Make sure the spring is in there properly (You do not want it to fly out of there).

Holding the spring down, with pliers carefully bend about 3" or 4" (more or less) on the inner portion of the spring in towards the center of the housing. This will allow the pulley pin to enter the retaining hole at the end of the spring properly.

Lay the pulley down over the spring, making sure that the pin on the pulley is secured to the retaining hole on the end of the spring. Install the spindle (center bearing gizzmo), bolt, nut, etc, whatever your particular manual starter may use.

The cord (nylon) should be roughly 72" long. Have a figure 8 knot in one end. Heat the other end so that you could form a point on it, wiping it with a rag when it's burning or hot to a melting point.

Now, with the starter housing still upside down, keeping a firm grip on that starter housing and also the pulley, start winding the pulley in the normal counter clockwise direction. Wind it as far as it will go, then carefully let it back off until the starter pulley cord hole is aligned with the housing cord outlet.

Hold the pulley there and insert the cord in through the inside of the pulley and out through the starter housing. Pull the cord through completely and get a good grip on it. Now let the pulley retract the cord, but hold onto the cord (don't let it fly in there).

If it's obvious that the cord is too long, figuring what will be needed within the handle, shorten it as needed.

Pull the cord out so that about two feet of the cord is exposed. Tie a slip knot so that the cord can't retract back.

Insert the cord into the handle and secure as needed, then release the slip knot allowing the cord to be withdrawn fully. That's all there is to it..