rope starter busted spring

[jasper60103]

'81 Johnson 25 hp.

Tried to start motor this morning and it wouldn't recoil. Never had a problem before.
Anyway, I opened it up and found a broken spring. Before I order the part, I wanted to know should I replace anything else? The pawl seems to operate like it should. As I said before I never had problems with the starter.
Also, can you give me some pointers how to rewind the spring? My OEM service manual shows how to do it with the special rewinder tool which I don't have.

Thanks.
jasper

 

[F_R]

Re: rope starter busted spring

If you haven't already done so, remove the pawl and links and center spindle from the pulley. Also, remove the rope by removing handle and pull the knot/rope from the pulley.

See the 1/8" hole in the pulley? Find a nail or something that will fit through it, and keep it handy for later.

Insert the spring into the housing by putting the outer loop over the pin. Then wind it in like coiling up a garden hose. Then put some grease on it, and install the pulley pin into loop. It may help to bend the spring a bit to get the loop in a convenient location.

Grease the spindle and insert into pulley, aligning pin. Install bolt and tighten.

Wind the pulley counterclockwise, all the way, then back it off one turn and insert that nail that you found. That will keep it from unwinding. DO NOT let the pulley get away from you and go flying back. The resulting backlash will wreck the spring.

Now you have all day to install the rope & handle. Put rope in pulley, behind the pin, and out the opening. Now put the handle on.

Hang onto rope, and remove nail and let it recoil.

Install the pawl and links.

15 minute job.

 

[samo_ott]

Re: rope starter busted spring

To answer your other question. The pawl and the springs look good.

And I cant believe that the starter looks identical on an '81 25hp as it does on my '55 25hp!

 

[jasper60103]

Re: rope starter busted spring

Thanks, F_R and Steve.
I will order the spring and let you know how it goes.

jasper

 

[jasper60103]

Re: rope starter busted spring

OK, I'm back.

I notice the rope is frayed near the knot in the pulley. So it makes sense to replace the rope now. I know the original rope is NLA. What is the best substitute?

FYI.
ROPE. CUT FROM 100 FT ROLL PART NO 316705. CUTTING LENGTH 72-1/4

 

[jasper60103]

Re: rope starter busted spring

F_R,
the instructions you provided were excellent, and every step went smoothly, but I have one final question.

I bought the proper rope (772578) and cut it exactly 72-1/4" long as specified in the manual. My problem is the timing mark on the pulley does not line up. I would need to cut off about 3 inches of rope for it to line up. Should I do this or leave it alone?

FYI. The rope is not stiff. I exercised the pulley a dozen or so times and it didn't make any difference.
Also, I noticed the old rope was maybe about 5 feet long. I don't know if the timing marks were aligned when I took it off though (edit: Second thought. How could I know, the spring was busted).

Thanks,

jasper

 

[BigB9000]

Re: rope starter busted spring

I don't think you have to worry about the timing marks?

 

[samo_ott]

Re: rope starter busted spring

I would cut a bit off. I like my pull starter's to engage a couple of inches out. I used to ignore the timing marks also until I sometimes would pull a foot or so out before it engaged. I didn't like that. I time them all now.

 

[Jerry_NJ]

Re: rope starter busted spring

Related, but a question.

I looks like all one has to do to remove the starter rope assembly is remove the three hold down bolts.. correct? And, is there any secrete need to put it back together, or does it just "drop in"?

I as as I am thinking I may have to pull the rope starter to gain access to the stator on my 9.9 Evinrude which has no spark.

Some diversion, not trying to "steal" the thread.

 

[samo_ott]

Re: rope starter busted spring

Yes, you should start a new thread.

Yes, remove the 3 screws and it pops off. and back on again.

No idea about the 9.9.

 

[jasper60103]

Re: rope starter busted spring

I would cut a bit off. I like my pull starter's to engage a couple of inches out. I used to ignore the timing marks also until I sometimes would pull a foot or so out before it engaged. I didn't like that. I time them all now.

Ok, I was a little confused at first, but now I understand the purpose of the timing marks. I will cut a few inches off. Thanks for clarifying, Steve.

 

[chiefcatchemall]

Re: rope starter busted spring

If you haven't already done so, remove the pawl and links and center spindle from the pulley. Also, remove the rope by removing handle and pull the knot/rope from the pulley.

See the 1/8" hole in the pulley? Find a nail or something that will fit through it, and keep it handy for later.

Insert the spring into the housing by putting the outer loop over the pin. Then wind it in like coiling up a garden hose. Then put some grease on it, and install the pulley pin into loop. It may help to bend the spring a bit to get the loop in a convenient location.

Grease the spindle and insert into pulley, aligning pin. Install bolt and tighten.

Wind the pulley counterclockwise, all the way, then back it off one turn and insert that nail that you found. That will keep it from unwinding. DO NOT let the pulley get away from you and go flying back. The resulting backlash will wreck the spring.

Now you have all day to install the rope & handle. Put rope in pulley, behind the pin, and out the opening. Now put the handle on.

Hang onto rope, and remove nail and let it recoil.

Install the pawl and links.

15 minute job.

Excellent method. Just got done doing mine. Awesome post. Thanks!