Evinrude 4hp E4BRCCS - Pull start not recoiling

[barrowmatt]

I have an Evinrude 4hp (EDIT: 1981) and the pull start is not recoiling, it feels as if it is jammed or sticking. Occasionally it will recoil a bit but then stick again. Having read through the forum I have already tried sraying WD40 in where ever I can without any success.

I have a feeling i'm going to have to dismantle it unless anyone can give me any other ideas?

Also, I did try to take the screws out that hold the top cover on and they seem to be extremely tight but hopefully I will be able to get them out. I assume the top case has to be removed to service the pull start? Will the assembly fall to bits and spit out springs when the top cover is removed, it does have a single bolt through the top cover.

Closest images I could find online are below, not exactly the same but looks the same design:

http://www.lakelandimages.co.uk/Forum pics/info_engine/Evinrude4hp/testrun2.jpg
http://www.boatsandoutboards.co.uk/images/pics/BMS138_1.jpg

Any help/advice how to solve this would be very much appreciated, it is in superb condition other than this and as my tender motor is stopping me from getting to my mooring

Thanks.

Matt

 

[Rick.]

Re: Evinrude 4hp E4BRCCS - Pull start not recoiling

You can pull it without having the spring attack you. As you remove it keep it pinched together with the center bolt in place but loosened right off. From there you need to remember you have the equivalent of a land mine in your hands LOL. Take very careful attention (pictures are a good idea) to the direction of the spring coils and where the rope enters the cup and where (at the back of the cup) the spring protrudes. There is a good way to wind the spring back into the cup fully covered in the OMC service manual(which you should get). I did a few without the manual but the OMC method is by far easier. Were junk clothes as you will be surprised how dirty you are at the end. Clean every thing in var-sol and then re-grease the spring and parts as you re-assemble. Best of luck. Rick.
http://epc.brp.com/Index.aspx?lang=E&s1=0282779c-b297-4b39-86da-02b1d0601226

 

[barrowmatt]

Re: Evinrude 4hp E4BRCCS - Pull start not recoiling

Thanks Rick,

Too late i'm afraid, I took the top off without the center bolt attached and yes the whole thing exploded on me!

I think I can see how it works, going to try and reassemble it now. I will try pulling it without the spring just to ensure everything is turning over correctly (which it was before).

Would anyone be able to tell me where the spring should be positioned, is it between the top case and the pull start wheel or between the pull start wheel and the engine. Also any idea how many turns? I don't have a manual, not sure what they are like to get hold of in the UK.

What I did notice is as I unscrewed the case bolts it recoiled, maybe some grease will help otherwise I may need to add a washed under each bolt? Is pressure from the case itself a common problem?

 

[Rick.]

Re: Evinrude 4hp E4BRCCS - Pull start not recoiling

Glad to hear it didn't eat you alive. The spring goes "between the pull start wheel and the engine". If you send me your email I could send some pictures of mine assembled. You should not have to add any washers as it will work well on it's own. Were you able to pull up the link I sent of the parts break down? Rick.

 

[barrowmatt]

Re: Evinrude 4hp E4BRCCS - Pull start not recoiling

I put the pulley wheel and case back together without the spring and it didn't want to turn over? I also tried with the spark plugs out and still the same. Either i've reassembled it incorrectly or the problem is more serious than just the recoiling.

Not sure where to look next, i'm cautious about removing the flywheel/starter assembly as I don't know what is inside and if it will fall apart or not!

I couldn't go directly to the link it took me to a login screen, I can access the parts diagrams though. I am looking at Evinrude 4hp 1988 but it doesn't look exactly the same?

 

[Daviet]

Re: Evinrude 4hp E4BRCCS - Pull start not recoiling

E4BRC = 1981, couldn't cross your model number, might want to double check it. Does this look like your starter?
http://www.ishopmarine.com/ishop/js...CatFilter=BRP&eCatSupFldr=supplier-100-005-EJ

 

[barrowmatt]

Re: Evinrude 4hp E4BRCCS - Pull start not recoiling

E4BRC = 1981, couldn't cross your model number, might want to double check it. Does this look like your starter?
http://www.ishopmarine.com/ishop/js...CatFilter=BRP&eCatSupFldr=supplier-100-005-EJ

That's the one, thanks. The diagrams make a lot more sense now.

 

[barrowmatt]

Re: Evinrude 4hp E4BRCCS - Pull start not recoiling

After a bit of guesswork and a lot of cursing it is finally back together and working (well it's turning over, not had fuel in it yet)

The pull start is completely enclosed within the top case between the case and pulley wheel, the problem with the sticking was that the top bolt had been loosened and the recoil spring had come out of the side of the wheel into the case area. There is a bit of play in the wheel with the case off, not sure if the flywheel reduces this when fitted so will have to keep an eye on this and if it happens again add a washer under the wheel.

The engine seemed to be a bit stuck but after putting a couple of bolts into the flywheel housing (assume they are for a flywheel puller) I turned it over with a spanner and all was fine.

Had a bit of hassle recoiling the pull start but once started it was relatively easy.