STARTER AND CHARGING SYSTEMS
42
4. Install a starter cup:
• Place the starter cup on the flywheel, with the
three dimples on the bottom of the starter cup
into the dimples in the flywheel
• Align the pin on the flywheel fan with the hole in
the starter cup. See Figure 6.3.
5. Install the flywheel nut and tighten it to a torque
of 47 - 52 ft-lbs (64 - 70 Nm).
Starter Rope
The most common failure mode for most recoil
assemblies is a broken rope.
NOTE: If the spring was not damaged when the
recoil sprung back, it is possible to simply
remove the remnants of the old rope and install
a new rope.
1. Remove the starter by following the steps
described earlier in this chapter.
2. Remove the old starter rope by prying out the
starter cord knot and pulling the rope out with it.
3. Cut a piece of #6 recoil rope 75” (1.9 meters)
long.
4. Heat fuse the ends of the starter rope, and tie a
double half-hitch in one end.
5. The rope may be easily installed from the out-
side-in. Pull the rope tight to seat the knot firmly
in the recess in the back of the pulley.
See Figure 6.4.
NOTE: It may be necessary to wind the pulley
clockwise to line up the hole in the pulley to the
hole in the starter housing. If so, use a punch or
screwdriver to block the pulley, preventing it from
rewinding.
See Figure 6.4.
6. Wind the spring 6 - 7 turns and block it with a
punch or screwdriver to keep it from rewinding.
Figure 6.3
Flywheel dimples
Starter cup
Alignment pin
Alignment hole
dimples
Figure 6.4
Rope inserted
from the inside
out
pulley blocked
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