MANUAL STARTER

Starter Assembly (Manual)

30
31
24 26
29 30
32
31
29

32
A
17
23 16
26
B

28 3 25
15
27 13
18
22 21 4
14

26
95 5
6

19
20

7
11 12
8
95
9 10

2
95
26 Cyanacrylate Adhesive (purchase locally)
95 2-4-C With Teflon (92-825407A12)

A -- 30 lb. in. (3.5 N·m)

B -- 110 lb. in. (12.5 N·m)

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 MANUAL STARTER

Starter Assembly (Manual)

TORQUE
REF.
NO. QTY. DESCRIPTION lb. in. lb. ft. N·m
RECOIL STARTER ASSEMBLY
-- 1
(USA-0G/BEL- & BELOW
RECOIL STARTER ASSEMBLY
-- 1
(USA-0G/BEL- & UP
HOUSING--starter
1
(USA-0G/BEL- & BELOW
1
HOUSING--starter
1
(USA-0G/BEL- & UP
2 1 SCREW (1/4-20) 135 11.0 15.3
3 1 RETAINING RING
4 1 PAD--felt
5 1 SPRING--starter
6 1 SHEAVE--starter
7 2 SPRING--cam
8 2 CAM
9 2 RETAINING RING--cam
10 1 CAM
11 1 SPRING--cam
12 1 ROPE--starter
13 1 HANDLE ASSEMBLY--starter rope
14 1 RETAINER
15 1 BUSHING--rope
16 1 SUPPORT--starter handle
17 2 SCREW--support to starter housing (M5x35MM)
18 4 SPACER--support screw
19 1 SUPPORT
20 2 NUT--support screw 30 3.4
21 1 LEVER--lock (LOWER)
22 1 ROLL PIN--lock lever
23 1 SPRING--upper lock lever
24 1 LEVER--lock (UPPER)
25 1 BUSHING
SCREW (M6 x 35)
3 NON SEAPRO/MARATHON 110 12.4
USA- 0G/BEL- & UP
26 2 SCREW (M6 x 20) NON SEAPRO/MARATHON
1 SCREW (M6 x 35)
110 12.4
USA- 0G/BEL- & BELOW
27 3 WASHER (.62x.255x.03) COMMERCIAL
28 3 NUT (M6 Nylon Insert) ENGINES 110 12.4
29 1 DECAL--high voltage
30 1 DECAL--servicing referral
31 1 DECAL-Caution Start in Gear (REMOTE CONTROL)
32 1 DECAL--emergency start procedures

90-826883R2 JUNE 1998 Page 8-3

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 MANUAL STARTER

Rewind Starter Assembly

Removal
CAUTION
DO NOT turn or cock fuel filter assembly when removing. Remove fuel filter by
pulling straight down. Turning or cocking fuel filter may break fuel line connec-
tion on filter.
1. Pry fuel filter from starter rope guide. DO NOT turn or cock filter; pull straight down.

53246

a - Filter 56800
b - Guide
2. Unsnap interlock link rod from lower lock lever.

56803

a - Link Rod
b - Lock Lever

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 MANUAL STARTER

3. Remove 3 bolts and lift rewind starter from engine.

a a

a - Bolts
b - Rewind Starter
Installation
1. Secure rewind starter to engine with 3 bolts. Apply Loctite 242 to threads of 3 mount-
ing bolts. Torque bolts to 110 lb. in. (12.4 N·m).

66 a

66
b
66

a a

66 Loctite 242 (92-809821)

a - Bolts -- Torque to 110 lb. in. (12.4 N·m)

b - Rewind Starter

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 MANUAL STARTER

2. Snap interlock link rod into lower lock lever.

56803

a - Link Rod
b - Lock Lever
CAUTION
Push filter straight up when installing. Turning or cocking filter may break fuel
line connection on filter.
3. Push ball of fuel filter into socket of rope guide. DO NOT turn or cock fuel filter.

53247
a - Filter
b - Guide

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 MANUAL STARTER

Starter Rope Replacement

1. Remove rewind starter from engine, as outlined previously.
NOTE: If starter is broken, remove all remaining rope from sheave.
2. Disengage starter interlock from starter sheave.
3. Pull starter rope handle out from rewind starter about 1 ft. (30.5cm) and tie a knot at
this point to prevent rope from being pulled back into rewind starter.
NOTE: 1999 Model and newer have a redesigned rope guide support which must be re-
moved before replacing starter rope.

57051

a - Interlock
b - Rope Guide Support (1999 Model and Newer)
4. Remove rope retainer from starter handle and rope.

b
53233

a - Starter Handle
b - Retainer

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 MANUAL STARTER

5. Install starter handle on new rope cut to a length of 66 in. (1676 mm). Tie a knot into
end of rope. Place knot into recess of rope retainer. Install rope retainer into starter
handle.

c
53233

a - Handle
b - Knot
c - Retainer
CAUTION
Starter sheave must be firmly held against spring tension to prevent spring from
unwinding.
6. Pull starter rope from rewind starter until rope is fully unwound from starter sheave.

57052
a - Rope
b - Sheave

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 MANUAL STARTER

7. While holding sheave in this position, lift knot from recess and pull all remaining rope
from sheave.

57053
a - Sheave
b - Knot
c - Recess
8. Turn sheave COUNTERCLOCKWISE until stop, indicating spring is wound tight.
9. Slowly turn sheave CLOCKWISE (with spring tension) until knot recess is aligned with
rope hole in starter housing.

57054

a - Sheave
b - Knot Recess
c - Rope Hole

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 MANUAL STARTER

10. Push end of new rope through rope holes in starter housing and starter sheave. Pull
end of rope out of knot recess.

b
c

57056

a - Rope
b - Holes
c - Knot Recess
11. Tie a knot into end of rope and pull knot back into knot recess.

57057

a - Knot
b - Knot Recess
12. Allow starter rope to be slowly rewound onto starter sheave.
13. Reinstall rope guide support, if applicable.

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 MANUAL STARTER

Disassembly
WARNING
When disassembling rewind starter, SAFETY GLASSES MUST BE WORN in case
spring should uncoil out of housing.
1. Remove starter rope as outlined previously.
2. With rope removed, allow sheave to slowly unwind to release spring tension.
3. Remove bolt securing cam and sheave to housing.

b
a

57055

a - Bolt
b - Sheave
4. Gently lift starter sheave from housing.
5. Rewind spring assembly may be replaced as required. DO NOT remove spring from
retainer. Spring and retainer are replaced as an assembly.

57058
a - Sheave
b - Rewind Spring

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 MANUAL STARTER

Cleaning and Inspection

1. Clean rewind spring assembly with solvent and dry with compressed air.
2. Inspect rewind spring (without removing spring from retainer) for kinks, burrs or break-
age. Replace assembly if necessary.
3. Inspect cam tension spring for damage. Replace as necessary.
4. Inspect starter sheave and housing for nicks, grooves, cracks and distortion especial-
ly in area of rope travel. Replace assembly if necessary.
5. Inspect starter rope for wear and replace if necessary.

Reassembly
1. Apply 2-4-C w/Teflon (92-825407A12) to rewind spring and cam tension spring.
2. Install rewind spring assembly into recoil housing positioning end of spring in notch.

c b a

53161

95

57059

95 2-4-C With Teflon (92-825407A12)

a - Rewind Spring
b - Notch
c - Cam Tension Spring

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 MANUAL STARTER

3. Install starter sheave into housing aligning notches in sheave with appropriate loca-
tions on recoil spring.

b
b

57060
a - Sheave
b - Alignment Notches
4. Secure cam to housing with bolt. Torque bolt to 70 lb. in. (7.9 N·m).

95

95

57055
95 2-4-C With Teflon (92-825407A12)

a - Cam
b - Bolt
NOTE: If, after tightening cam retaining bolt, sheave does not move freely, sheave is not
aligned properly with recoil spring retainer. Remove cam retainer bolt and check align-
ment of sheave with spring retainer.
5. Apply 2-4-C w/Teflon to edge of cam that contacts both pawls.
6. Install starter rope as outlined previously.
7. Install rewind starter as outlined previously.

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