Poulan 1600 User Manual - Page 18

E.

STARTER

ROPE

•

This

is

a

complicated

and

potentially

hazardous

task.

It

is

recommended

that

only

a

gratified

service

dealer

perform

this

repair.

18.

Turn

the

pulley

clockwise

until

all

the

rope

is

wrapped

onto

the

pulley.

19.

Pull

out

the

rope

by

the

handle

(approximately

12

")

and

hold

the

pulley.

20.

Pull

the

12

inch

slack

in

the

rope

into

the

inside

of

the

®WARNING

fan

housing

and

catch

rope

in

pulley

notch.

Figure

Always

wear

eye

protection

and

gloves

when

servicing

30.

the

starter

rope.

The

recoil

spring,

located

beneath

the

21.

Hold

the

rope

taut

and

make

2

complete

turns

of

the

pulley,

is

under

tension.

If

the

spring

fl

ies

out,

serious

pulley

counterclockwise

to

place

tension

on

injury

can

result.

the

spring.

Continue

to

hold

the

pulley

to

retain

tension.

•

To

repair

or

replace:

22.

AIigh

pulley

notch

with

rope

exit

hole,

release

slack

1_

Disconnect

spark

plug

wire.

in

the

rope

and

pull

starter

handle

to

the

full

extent

2.

Drain

all

fuel

from

tank.

of

the

rope.

Release

the

pulley

and

slowly

allow

the

3.

Remove

the

two

screws

and

two

washers

from

the

fuel

tank.

Figure

24.

Set

fuel

tank

aside.

4.

Remove

the

five

screws

from

fan

housing.

Figure

25.

5.

Separate

fan

housing

from

shroud

about

2

inches.

rope

to

wind

around

23.

Reverse

procedure

to

shroud.

for

the

pulley

re

-assembly

of

fan

housing

6.

Slide

high

tension

lead

giommet

from

slot

in

fan

housing.Figure

26.

7.

Separate

fuel

line

leaving

the

connector

in

the

end

REMOVE

THE

FIVE

SCREWS

0

AIR

FILTER

attached

to

the

fuel

tank.

Figure26.

8.

Separate

the

fan

housing

completely

from

the

shroud.

Figure

26.

REMOVE

SCREW

REMOVE

SCREW

tt

9.

If

the

starter

rope

is

not

broken,

release

the

spring

tension

by

pulling

about

12

inches

of

rope

from

the

pulley

and

catch

the

rope

in

the

notch

as

shown.

Figure30.

CAUTION:

Be

sure

the

tension

on

the

starter

spring

is

released

by

rotating

the

pulley

clock-

wise

with

your

finger

while

pushing

down

on

the

pulley

with

your

hand.

10.

Remove

screw

from

the

starter

pulley

very

carefully.

Rotate

the

pulley

clockwise

until

no

spring

tension

is

felt

and

carefully

lift

the

pulley

out

of

the

fan

housing.

Figure

29.

Remove

the

old

rope.

11.

Move

away

from

the

fuel

tank

with

the

rope

to

be

installed.

Use

a

match

and

melt

both

ends

of

the

rope

to

prevent

fraying.

12.

Pull

the

melted

ends

through

a

thick,

clean

rag

while

the

rope

is

still

hot

to

obtain

smooth,

pointed

tips.

13.

Insert

one

end

of

the

rope

through

the

handle

and

secure

with

a

knot.

14.

Insert

the

free

end

of

rope

through

rope

exit

hole

into

the

inside

of

the

fan

housing.

15.

Guide

rope

inside

pulley,

then

up

through

the

pulley

ratchet

side

of

pulley

hole

to

the

outside

by

pushing

the

rope

through

from

the

hole

on

the

spring

cam

side

with

a

small

Phillips

screwdriver_

Figure

27.

16.

Wrap

rope

counterclockwise

4—+

around

pulley

ratchet

and

tuck

loose

end

back

under

rope

where

it

comes

out

of

hole.

Leave

a

1/4

to

1/2

inch

tail

laying

flat

on

the

top

of

the

pulley.

The

rope

tail

must

not

extend

beyond

the

edge

of

the

pulley.

Figure

28.

17.

Carefully

replace

pulley

in

the

housing.

Be

sure

the

pulley

is

all

the

way

down.

Replace

washer

and

screw

and

tighten.

Figure

29.

Figure

24

Figure

2.5

FAN

HOUSING

-4w

*

fir

FUEL

LINE

ve

a

et

C.

"

Qom

IGNITION

MODULE

"OFF"

SHROUD

BUTTON

HIGH

TENSION

TERMINAL

LEAD

GROMMET

Figure

26

SPRING

CAM

UNDERSIDE

HOLE

0

0

0

•

SCREWDRIVER

ROPE

TAIL

PULLEY

RATCEIE

I

Figure

27

Figure

2.8

18

Poulan 1600 User Manual - Page 18

housing.

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