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78/83/90 Series Horizontal Shaft Engines
74
5. Carefully lift the spring and pulley out of the recoil
housing.
See Figure 6.9.
NOTE: If the spring is undamaged, but has been
removed from the pulley, the spring may be
re-wound. Hook the end of the spring into
the slot in the outer lip of the recess of the
pulley and wind the spring into the recess in
a counter-clockwise direction.
NOTE: Evaluate the damage, including parts prices
and local labor rates. In some parts of the
country, it makes economic sense to replace
the complete assembly, in other areas labor
rates favor repair.
6. To re-assemble, apply a small amount of lithium-
based chassis grease to the surface of the recoil
housing that contacts the spring.
NOTE: Use low temperature grease on the snow
engines.
7. Carefully position the pulley and spring in the recoil
housing. Rotate the pulley gently counter-clockwise
until the spring seats, allowing the pulley to fall into
position.
8. Install the torsion springs and pawls so that the long
arm of the spring reaches outside of the pawl, and
draws it toward the center of the assembly.
See Figure 6.10.
NOTE: The rolled end of the pawl fits in the recess
in the starter pulley. The bent end engages
the starter cup. The roll faces inward and the hook faces outward.
NOTE: The extrusions on the pressure plate should fall inside of the pawls as the starter is assembled.
NOTE: Drag on the pressure plate, from the friction between the compression spring and the head of the
shoulder screw causes these extrusions to force the pawls outward, engaging the starter cup.
9. Apply a small amount of thread locking compound such as Loctite 242 (blue) to the threads of the shoulder
screw, and install the screw. Tighten it to a torque of 71 - 89 in-lb. (8 - 10 Nm).
10. Install the starter rope by following the steps described in the previous section of this chapter.
11. Install the starter and tighten the starter nuts to a torque of 53 - 71 in-lbs (6-8 Nm).
Figure 6.9
Pulley
Spring
Housing
Lithium grease
! CAUTION! CAUTION
The recoil spring is under tension
and can release as the pulley is
removed.
Eye protection should be worn while removing the
starter pulley.
Figure 6.10
Pawls
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