Poulan 1994-04 User Manual - Page 22

F.

STARTER

ROPE

•

Replace

a

Starter

Rope

that

breaks.

A

DANGER

Never

start

engine

with

clutch

shroud

removed.

The

clutch

will

fly

apart

and

cause

serious

injury.

A

WARNING

Do

not

remove

the

pulley

tab

and

screw

or

the

pul-

ley.

The

spring

beneath

the

pulley

is

under

tension

and

can

fly

out

and

cause

serious

injury.

If

any

part

of

pulley

housing

assembly

is

damaged

other

than

rope,

do

not

use

tool.

Take

it

to

your

Service

Dealer.

1.

Disconnect

spark

plug

wire.

Figure

31

.

2.

Remove

the

screw

and

nut

from

the

throttle

trigger

housing.

Figure

31

.

3.

Hold

throttle

trigger

away

from

foam

grip

and

remove

barrel

end

of

throttle

cable

from

trigger.

4.

Carefully

pull

throttle

cable

out

of

foam

grip.

5.

Remove

the

four

clutch

shroud

screws

with

the

small

hex

wrench

provided.

Figure

31.

6.

Separate

clutch

shroud

from

engine.

Figure

31

.

A

DANGER

Use

only

a

hand

tool

to

remove

the

clutch.

Do

not

use

any

type

of

motorized

tool

or

strike

the

clutch

in

any

way.

Otherwise,

the

clutch

will

fly

apart

and

cause

serious

injury.

7.

Hold

the

"Flats"

of

the

clutch

with

an

adjustable

wrench.

Figure

32

(inset)

and

remove

the

nut

coun

terclockwise

with

a

9/16"

socket

wrench.

NOTE:

Clutch

will

slide

off

the

crankshaft

intact.

D

o

no

disassemble

clutch.

8.

Remove

the

cupped

washer,

clutch,

and

large

fl

at

washer

as

shown

in

Figure

32

.

9.

Remove

pulley

housing

from

engine.

Figure

32

.

10.

Remove

the

rope

retainer

screw

and

remove

any

re-

maining

rope.

Figure

33

.

11.

Hold

pulley

housing

as

shown

in

Figure

34

.

Hand

turn

the

pulley

clockwise

as

far

as

it

will

go.

12.

Turn

the

pulley

counterclockwise

until

the

pulley

notch

is

aligned

with

the

housing

notch

next

to

the

pulley

tab

and

screw.

Figure

34

.

13.

Next,

turn

the

pulley

one

complete

turn

counterclock-

wise

until

the

notches

are

aligned

again.

14.

Insert

hex

wrench

into

hole

formed

by

notches

to

hold

pulley

in

position.

Figure

34

(inset

—right).

15.

Use

a

42

length

of

replacement

rope.

16.

Move

away

10

feet

(3

meters)

from

the

fuel

tank

with

the

replacement

rope.

Use

a

match

and

melt

both

ends

of

the

rope

to

prevent

fraying.

17.

Pull

melted

ends

through

a

thick,

clean

rag

while

rope

is

still

hot

to

obtain

smooth,

pointed

ends.

18.

Insert

one

end

of

the

rope

through

the

handle

and

se-

cure

with

a

knot.

Leave

a

3/16"

pigtail

behind

the

knot.

Figure

34

(inset

—left).

19.

Insert

the

other

end

of

the

rope

through

the

rope

exit

hole

into

the

inside

of

the

housing,

into

the

pulley

and

up

through

the

pulley

hole.

Figure

34

.

20.

Wrap

the

rope

counterclockwise

around

the

pulley

ratchet

and

tuck

loose

end

under

the

rope

at

the

pulley

hole.

Figures

33

&

34

.

Leave

a

1"

tail

laying

fl

at

on

top

of

the

pulley

between

the

retainer

rib

and

the

retainer

screw/post.

Figure

34

.

21.

Reinstall

the

rope

retainer

screw

into

the

screw

post.

Figure

33

.

Tighten

until

the

washer

is

snug.

NOTE:

Do

not

overtighten

screw.

Overtightening

the

screw

can

cause

threads

in

screw

post

to

strip

out.

22.

Hold

the

rope

taut

at

the

rope

exit

hole

so

the

pulley

will

not

move.

Remove

hex

wrench.

23.

Slowly

feed

rope

into

the

pulley

housing.

24.

Make

sure

spacer

is

in

place

as

shown

in

Figure

32

.

Reverse

ste

s

1

through

10

to

re

—assemble.

When

reinstalling

the

clutch,

t

g

ten

t

e

nut

until

the

cupped

washer

is

flat-

tened

against

the

clutch.

Over

or

under

tight-

ening

nut

can

cause

engine

damage.

A

U

•

Clutch

Shroud

Screws

Throttle

Trigger

Screw

►

,of

Spark

Clutch

Plug

Wire

Shroud

:la—

Throttle

Trigger

Nut

Figure

31

Pulley

Nut

Housing

ky

cnr

0

In

0

0

NZ'

Spacer

Cupped

Washer

(Curved

Toward

Clutch)

Nut

Large

Flat

Washer

Clutch

•

4

,

s*.

a

Figure

32

Pulley

Rope

Retainer

Screw

Washer

Rope

Tail

Screw

Post

Figure

33

3/16"

Pulley

Ratchet

Pulley

Notch

Pulley

Hole

0

‘‘.

Housing

Notch

Hex

Wrench

Rope

Exit

Hole

O

Figure

34

O

Retainer

ib

Rope

Tail

Pulley

Tab

and

Screw

—

22

—

Poulan 1994-04 User Manual - Page 22

Starter

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