Poulan 1992-06 User Manual - Page 18

C.

STARTER

ROPE

le

Replace

a

broken

starter

or

a

rope

that

is

badly

frayed.

NOTE:

A

recoil

spring

li

es

beneath

the

pulley

and

is

under

tension.

If

the

recoil

spring

is

dis-

turbed,

considerable

time

and

effort

will

be

required

to

reinstall.

For

this

reason

you

may

want

to

let

a

qualified

service

dealer

handle

this

re-

pair.

Ifyou

try

to

repair

the

starter

rope

and

the

re-

coil

spring

pops

out,

take

the

unit

to

your

dealer.

A

WARNING

Always

wear

eye

protection

when

servicing

the

starter

rope.

The

recoil

spring

beneath

the

pulley

is

under

tension.

If

the

spring

pops

out,

se-

rious

injury

can

result.

1.

Remove

the

four

screws

on

the

side

of

the

fan

housing.

Figure

37

.

CAUTION:

Do

not

mix

chrome

-colored

fan

housing

screws

with

the

black

-colored

cyl-

inder

shroud

screws.

Other

than

color,

these

screws

are

similar

in

appearance;

but

if

in-

terchanged,

they

can

strip

out

and/or

cause

permanent

engine

damage.

2.

Remove

the

fan

housing.

3.

If

the

starter

rope

is

not

broken,

release

the

springtension

by

pulling

about

10

inches

of

rope

from

the

inpulley

as

shown

in

Figure

38

.

Catch

the

rope

one

of

the

notches.

Figure

38

.

4.

Carefully

turn

the

pulley

counterclockwise

until

the

spring

tension

is

released.

5.

Remove

the

pulley

screw

in

the

center

of

the

pulley.

Be

sure

to

note

the

position

of

the

cam

when

removing

it

from

the

pulley.

Figure

39

.

6.

Lift

the

pulley

carefully

while

gently

twisting

it

counterclockwise.

7.

Remove

the

rope

retainer

screw

and

remove

the

old

rope.

Figure

39

.

8.

Move

away

from

the

fuel

tank

and

melt

the

end

of

the

rope

to

be

installed.

9.

Allow

the

melted

end

to

drip

once.

Then,

while

the

rope

is

still

hot,

pull

the

melted

end

through

a

rag

to

obtain

a

smooth,

pointed

end.

10.

Insert

one

end

of

the

rope

through

the

handle

and

secure

with

a

knot.

Leave

a

3/16"

-

pigtail

be-

hind

the

knot.

Figure

40

(inset).

11.

Feed

the

rope

through

the

round

starter

rope

hole

in

the

fan

housing.

Figure

39

12.

Guide

the

rope

inside

the

pulley,

then

up

through

the

pulley

hole

(on

the

pulley

ratchet

side).

Figure

39

.

It

might

be

necessary

to

in-

sert

a

small

screwdriver

through

the

underside

hole

to

push

the

rope

through

the

pulley

hole.

Figure

39

(inset).

13.

Tie

a

knot

in

the

end

of

the

rope

leaving

no

more

than

3/8

to

1/4

inch

tail

and

pull

the

knot

snugly

into

the

corner

of

the

groove

m

the

pulley.

Pull

the

rope

tightly.

14.

Tuck

the

tail

on

the

rope

knot

into

the

inner

curved

section

to

avoid

interference

with

the

flywheel.

15.

Set

the

pulley

into

the

housing;

push

it

down

and

engage

the

spring.

16.

Replace

and

tighten

the

pulley

screw.

Make

sure

the

starter

dog,

retainer,

cam,

and

wave

washer

are

positioned

and

installed

properly.

Fig-

ure

39

.

NOTE;

Make

sure

the

cam

is

installed

on

the

starter

dog

in

the

direction

shown

in

Figure

39

,

Also,

make

sure

the

wave

washer

is

seated

around

the

top

outer

edge

of

the

retainer

and

not

caught

between

the

top

of

the

retainer

and

the

pulley

screw.

17.

Pull

out

10

inches

of

rope.

Catch

the

rope

in

the

slot

in

the

pulley.

Figure

40

.

18.

Turn

the

pulley

clockwise

to

wind

up

the

spring

until

it

will

turn

no

more

without

forcing.

Hold

the

pulley

by

hand.

Do

not

let

go

of

the

pulley.

Let

the

pulley

slowly

unwind

one

full

turn

and

release

the

rope

from

the

slot.

Continue

to

hold

the

pulley.

19.

Hold

the

pulley

and

pull

the

starter

rope

to

the

full

extent

of

length.

Let

the

rope

rewind

slowly.

20.

Reinstall

the

fan

housing

using

the

chrome

—co-

lored

screws.

Tighten

the

screws

securely.

th

at

Remove

Chrome

Colored

Screws

(See

Caution

under

Step

1)

Figure

37

Notch

Turn

Pulley

Counterclockwise

To

Release

Tension

4.

Phillips

Screwdriver

Starter

Rope

Hole

Figure

38

Pulley

Screw

Cam

Wave

Washer

-0--

Retainer

Starter

tti

Dog

dl

fill

3/16"

Figure

39

•

Notch

Figure

40

-

18

-

Poulan 1992-06 User Manual - Page 18

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