Re: 1968 OMC Recoil Problems
no grease between the pulley and the post makes it seize up quick.
Boobie told you in post reply #9..... "Only some light grease on the pulley spool area.", meaning Do Put some grease on that area between the pulley and the spindle. Did you miss that?
On the graphic below, note that the pawl(s) go between the flat portion of the cup washer and the nylon bushing. The method of putting the starter together bollows the graphic.
(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Insert the cord into the handle and secure as needed, then release the slip knot allowing the cord to be withdrawn fully.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..
