Engine: Starter Rope Won't Retract

The pulley houses the pull rope and the recoil spring. The pull rope winds around the outside of the pulley. The wound recoil spring is mounted on the inside of the pulley. If the pulley is broken or cracked in any way, it can cause a malfunction, such as getting jammed up. To inspect it, remove the starter and inspect the pulley for any signs of damage that might be causing it to get stuck, and replace if needed. To replace, pull the starter rope all the way out and insert a small screwdriver to lock the pulley in place against the starter housing. Next, remove the rope, then remove the screwdriver to release any tension on the recoil spring by rotating the pulley. Loosen the center bolt to remove the friction plate and remove the old pulley, then install the new pulley by aligning it with the housing post. Next, rotate the pulley to tighten the recoil spring, reinsert the screwdriver and attach the rope, then allow the rope to wind up slowly, before reinstalling back onto engine.

The recoil spring retracts the rope back into the starter after you pull the rope to start the engine. If the rope does not recoil, the spring needs to be recoiled manually or replaced, depending on the problem with the spring. Remove the starter from the engine. Remove the center bolt, cap, and pulley from the starter housing. Inspect the recoil spring. If the spring is broken it will need to be replaced; if not, the spring can be recoiled. The spring only goes in one way on the locking tabs, so this is easy. Make sure the spring ends are bent properly to lock into the slots on the pulley and then on the starter housing. Remove the starter rope. Attach one end of the spring into the slot on the pulley and wind it up on the inside, not allowing it to pop out. Reattach the pulley to the starter housing and slowly rotate the pulley to get the spring to grab and lock into place on the starter housing. This may take some practice. Next, reinstall the center screw and cap to secure the pulley to the starter housing. Re-tension the spring by rotating the pulley in the proper direction, so when you let it go it will retract the rope. Once you have determined the correct direction, start winding up the spring about 5 to 6 times to create the tension on the spring. Insert a small screwdriver into the pulley and housing to hold the pulley in place with the tension on the spring. Next, insert the rope through the starter housing and through the pulley and make a knot to secure the rope to the pulley. Pull the knot back to the pulley, then hold the pulley tight and remove the screwdriver holding the pulley in place, letting it retract and winding up the starter rope. Reattach the starter back onto the engine and secure it down.

The starter turns the engine over in order to get it to run on its own. When you pull the rope, centrifugal force sends the pawls inside the starter outwards, which lock onto the flywheel and turn the engine over. The recoil spring then retracts the rope. Replacing the starter is the quickest and the easiest way of getting your engine to run again without repairing the starter itself. To replace the starter, remove the bolts holding down the starter and remove. Install the new starter.

The recoil spring retracts the rope back into the starter after you pull the rope to start the engine. If the rope does not recoil, the spring needs to be recoiled manually or replaced, depending on the problem with the spring. Remove the starter from the engine. Remove the center bolt, cap, and pulley from the starter housing. Inspect the recoil spring. If the spring is broken it will need to be replaced; if not, the spring can be recoiled. The spring only goes in one way on the locking tabs, so this is easy. Make sure the spring ends are bent properly to lock into the slots on the pulley and then on the starter housing. Remove the starter rope. Attach one end of the spring into the slot on the pulley and wind it up on the inside, not allowing it to pop out. Reattach the pulley to the starter housing and slowly rotate the pulley to get the spring to grab and lock into place on the starter housing. This may take some practice. Next, reinstall the center screw and cap to secure the pulley to the starter housing. Re-tension the spring by rotating the pulley in the proper direction, so when you let it go it will retract the rope. Once you have determined the correct direction, start winding up the spring about 5 to 6 times to create the tension on the spring. Insert a small screwdriver into the pulley and housing to hold the pulley in place with the tension on the spring. Next, insert the rope through the starter housing and through the pulley and make a knot to secure the rope to the pulley. Pull the knot back to the pulley, then hold the pulley tight and remove the screwdriver holding the pulley in place, letting it retract and winding up the starter rope. Reattach the starter back onto the engine and secure it down.

The friction plate or drive plate is part of the housing for the springs and the pawls inside the starter. This part can wear over time or even break, since many are made from plastic. To check the operation of this part, remove the starter from the engine. A broken one should be noticeable right away. Pull the cord to check the operation of the pawls. If they are not coming out and retracting properly, there may be a problem with the plate. Remove the center bolt and cap and remove the plate. Inspect for damage, foreign objects, or a build up of dirt on the inside that can impact the performance of the plate. Clean or replace the plate with a new one and reinstall the springs and pawls. Reinstall back into the starter and tighten the bolt down. Finally, reinstall the starter back on to the engine.

The rope feeds through the starter housing and is attached to the pulley on the inside of the pulley. As the rope ages, it can become frayed and start catching on the inside of the starter, causing more and more damage to the rope, which can cause it to get hung up and not retract. Eventually the rope will break. To install a new rope, remove the starter from the engine. Cut the old rope off under the knot at the pulley and pull out the old rope. Next, you have to reset the tension on the recoil spring. Rotate the pulley in the proper direction approx 5 -6 times for the proper tension on the recoil spring and insert a small screwdriver through the pulley, into the starter housing to lock it into place. Install the new rope through the hole on the starter housing and the hole on the pulley. Once installed, remove the screwdriver and slowly let the pulley recoil the new rope onto the pulley. Pull the rope out and let it retract a few times, making sure it is good. Reinstall the starter back onto the engine.

The starter clutch takes the place of the spring-loaded pawls that lock onto the flywheel, where they are housed as a unit inside the starter housing with the pulley and recoil spring. The clutch uses ball bearings in its place and is mounted onto the crankshaft instead. The rope, pulley, and recoiler are still mounted inside the starter housing. Remove the starter and the fan shroud to get access to the starter clutch. Next, use a pry bar to remove the clutch. Use the pry bar by locking it in place with the fins on the flywheel to prevent movement. Use channel locks to gently release the tightness of the clutch, then thread it off. Install the new clutch and tighten down with channel locks, then remove the pry bar. Reinstall the fan shroud and the starter cover.