Poulan 1600 User Manual - Page 18
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E. STARTER ROPE • This is a complicated and potentially hazardous task. It isrecommended thatonlya gratifiedservice dealer perform this repair. ®WARNING Always wear eye protection and gloves when servicing thestarter rope. The recoil spring, located beneath the pulley, is under tension. If the spring flies out, serious injury can result. • To repair or replace: 1_ Disconnect spark plug wire. 2. Drain all fuel from tank. 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. 6. Slide high tension lead giommet from slot in fan housing.Figure 26. 7. Separate fuel line leaving the connector in the end attached to the fuel tank. Figure26. 8. Separate the fan housing completely from the shroud. Figure 26. 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. Useamatch and melt both endsofthe rope to prevent fraying. 12. Pull themelted endsthrough 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 holeon thespring camside 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 isall thewaydown. Replace washerand screw and tighten. Figure 29. 18 18. Turn the pulley clockwise wrapped onto the pulley. until all the rope is 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 fan housing and catch rope in pulley notch. Figure 30. 21. Hold the rope taut and make 2 complete turns of the pulley counterclockwise to place tension on the spring. Continue to hold the pulley to retain tension. 22. AIigh pulley notch with rope exit hole, release slack in the rope and pull starter handle to the full extent of the rope. Release the pulley and slowly allow the rope to wind around the pulley 23. Reverse procedure for re-assembly of fan housing to shroud. AIR FILTER REMOVE THE FIVE SCREWS 0 REMOVE SCREW REMOVE SCREW tt Figure 24 FAN HOUSING-4w FUEL LINE * fir Figure 2.5 IGNITION MODULE vea "OFF" SHROUD BUTTON et C." HIGH TENSION TERMINAL Qom LEAD GROMMET Figure 26 UNDERSIDE HOLE SPRING CAM 0 0 • 0 PULLEY RATCEIE ROPE TAIL I SCREWDRIVER Figure 27 Figure 2.8