Recoil Starter

Manual Starter
Section 8A - Recoil Starter
Table of Contents

Recoil Starter Components..............................8A-4 Recoil Starter Assembly...........................8A-8

Recoil Starter...................................................8A-6 Recoil Starter Installation........................8A-12
Recoil Starter Removal.............................8A-6 Neutral Interlock Cable Adjustment........8A-14
Recoil Starter Disassembly.......................8A-7

8
A

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Recoil Starter

Lubricant, Sealant, Adhesives

Tube Ref No. Description Where Used Part No.
7 Loctite 271 Threadlocker Threads of the friction plate retaining bolt 92-809819
Recoil housing
95 2-4-C with Teflon Starter pawl bore on the recoil sheave 92-802859A1
Friction plate

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Notes:

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Recoil Starter

Recoil Starter Components

29 32
33
34
30 30
31

23
25

27 26

24

3 20
28 1
21
22

2
20
21 19

5
4
6

8
7
9

10

11 18
12
13 14

15
16
17 16664

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 Recoil Starter

Recoil Starter Components

Torque
Ref.
No. Qty. Description Nm lb. In. lb. ft.
1 1 Recoil starter
2 1 Starter housing
3 1 Spring
4 1 Starter handle
5 1 Cap
6 1 Starter lock
7 1 Starter rope
8 1 Starter spring
9 1 E-ring
10 1 Reel
11 1 Friction spring
12 1 Friction plate
13 1 Bolt 6 53
14 1 Ratchet
15 1 Ratchet guide
16 1 Return spring
17 1 Starter pulley
18 3 Screw (M6 x 16) 6 53
19 1 Seal
20 3 Bolt 6 53
21 3 Washer
22 2 Nut
23 1 Starter lock cam spring
24 1 Lock cable
25 1 Belt cover
26 2 Collar
27 1 Bracket
28 1 Screw (M6 x 16) 6 53
29 2 Bolt 6 53
30 4 Washer
31 2 Collar
32 2 Bolt 6 53
33 1 Decal - Spark plug (with resistance)
34 1 Decal - Caution

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Recoil Starter

Recoil Starter
Recoil Starter Removal
1. Remove the four bolts securing the timing belt cover to the cylinder block.
2. Remove the three bolts securing the recoil assembly to the engine block.

a
b

9698

a - Bolts securing the recoil assembly b - Bolts securing timing belt cover (4)
(3)

3. Remove the bolt securing the harness connector bracket to the intake manifold.

20523

4. Remove the timing belt cover.

5. Do not lose the T-nuts located in the recoil housing assembly.

20513

6. Pull the neutral interlock cable to disengage the neutral interlock cable from the recoil
housing.

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7. Lift the neutral interlock cable up and remove the neutral interlock cable tension spring
from the recoil housing.

a
b

9696

a - Neutral interlock cable tension b - Neutral interlock cable

spring

Recoil Starter Disassembly

! WARNING
Uncontrolled release of the rewind spring can injure. Wear eye protection when servicing
the rewind starter.

1. Cut or untie the recoil rope from the recoil handle.

2. Slowly allow the recoil starter sheave to unwind completely.
3. Rotate the recoil starter sheave clockwise to disengage the starter recoil spring from
the sheave.
4. Remove the bolt securing the recoil friction plate to the recoil housing. Remove the
recoil friction plate.

b d
a
c

9719

a - Recoil rope c - Bolt securing recoil friction plate

b - Recoil sheave d - Rotate recoil sheave clockwise

5. Carefully remove the recoil starter sheave.

6. Remove the recoil spring if replacement is needed.
7. Disengage the interlock lever spring from the recoil lock.

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8. Pinch the recoil lock retainer and push the recoil lock out of the recoil housing.

a b

9723

a - Recoil lock c - Recoil lock retainer (pinch to

b - Interlock lever spring remove)

9. Remove the E-ring securing the starter pawl to the starter sheave.

9725

10. Push the starter pawl out of the starter sheave.

Recoil Starter Assembly
! WARNING
Uncontrolled release of the rewind spring can injure. Wear eye protection when servicing
the rewind starter.

1. Lubricate with 2-4-C with Teflon the area of the recoil housing where the recoil spring
is located.
2. Install the recoil spring into the recoil housing.

a
b

9726

a - Recoil spring b - Lubricate with 2-4-C with Teflon

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Tube Ref No. Description Where Used Part No.

95 2-4-C with Teflon Recoil housing 92-802859A1

3. Tie a knot on one side of the recoil rope and insert the recoil rope through the recoil
sheave.
4. Thread the recoil rope through the recoil sheave as shown.
5. Pull the recoil rope tight in the recoil sheave.

9727

a - To recoil handle

6. Assemble the recoil pawl as shown.

9728

7. Lubricate the starter pawl bore on the recoil sheave with 2-4-C with Teflon.
8. Install the starter pawl return spring onto the recoil sheave.
9. Install the starter pawl onto the recoil sheave.

a b

9730

a - Starter pawl b - Starter pawl return spring

Tube Ref No. Description Where Used Part No.

Starter pawl bore on the recoil
95 2-4-C with Teflon 92-802859A1
sheave

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10. Secure starter pawl with the E-ring retained during disassembly.

9725

11. The recoil sheave catch on the recoil sheave must interlock with the recoil spring for
the recoil to function properly.

b
9732

a - Recoil spring b - Recoil sheave catch

12. Install the recoil sheave onto the recoil housing.

13. With a slight downward pressure, rotate the recoil sheave counterclockwise to engage
the spring into the catch on the recoil sheave. When the spring is properly positioned
on the recoil sheave, resistance will be present while winding the recoil sheave in a
counterclockwise rotation.
14. Install the friction plate spring onto the friction plate. Lubricate the friction plate with
2-4-C with Teflon.

a b

c
9740

a - Friction plate spring c - Lubricate with 2-4-C with Teflon

b - Friction plate

Tube Ref No. Description Where Used Part No.

95 2-4-C with Teflon Friction plate 92-802859A1

15. Insert the friction plate spring through the wire loop.
16. Align the tabs on the recoil housing with the holes on the friction plate.

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17. Apply Loctite 271 to the friction plate retaining bolt. Tighten the friction plate retaining
bolt to the specified torque.

c
d 9741

a - Recoil pawl c - Friction plate spring

b - Friction plate retaining bolt d - Wire loop

Description Nm lb. in. lb. ft.

Friction plate bolt 6 53

Tube Ref No. Description Where Used Part No.

Threads of the friction plate
7 Loctite 271 Threadlocker 92-809819
retaining bolt

18. Insert the recoil rope into the guide and through the recoil housing.
19. Insert the rope end through the recoil handle.
20. Tie a knot as shown. Place the rope knot into the rope retainer and insert into the recoil
handle.

9748

21. Insert the recoil rope into the notch on the recoil sheave.
22. Wind the recoil sheave three turns counterclockwise to preload the recoil spring.

a b

d
9743

a - Recoil rope c - Recoil rope guide

b - Recoil sheave notch d - Recoil housing opening

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Recoil Starter

23. Allow the recoil rope to retract into the recoil sheave.
24. Ensure the recoil rope retracts and extends fully.
25. Insert the recoil lock into the recoil housing.
26. Push the recoil lock until it snaps into place.

a b

9749

a - Recoil lock c - Recoil lock bore

b - Recoil sheave

27. Place the interlock lever spring onto the recoil lock.

a b

9723

a - Recoil lock c - Recoil lock retainer

b - Interlock lever spring

Recoil Starter Installation

1. Install the neutral interlock cable tension spring onto the recoil housing catch and the
neutral interlock cable end.

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2. Pull on the neutral interlock cable and insert the cable end into the neutral interlock
cable retainer on the recoil housing.
a
b

9717

a - Recoil housing catch b - Neutral interlock cable retainer

3. Install the recoil assembly onto the cylinder block and secure with three bolts. Do not
tighten the bolts at this time.
4. Ensure the T-nuts are installed in the recoil housing assembly.

20513

5. Install the timing belt cover. Ensure the aft mounting of the timing belt cover is supported
by two spacers.
6. Align the harness connector bracket with the timing belt cover and install a bolt. Do not
tighten the bolts at this time.
7. Align the harness connector bracket with the intake manifold bolt hole. Secure the
harness connector bracket with a bolt. Tighten the bolt to the specified torque.

20523

Description Nm lb. in. lb. ft.

Harness connector bracket bolt 6 53

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Recoil Starter

8. Install the remaining timing belt cover bolts. Tighten the timing belt cover bolts and the
recoil housing bolts to the specified torque.

a
b

9698

a - Bolts securing the recoil assembly b - Bolts securing timing belt cover (4)
(3)

Description Nm lb. in. lb. ft.

Recoil retaining bolts (3) 6 53
Timing belt cover retaining bolts (4) 6 53

Neutral Interlock Cable Adjustment

1. Ensure the tiller handle control cables are properly adjusted.
2. Ensure the tiller handle is in neutral.
3. Loosen the interlock cable nuts.

22639

a - Throttle cam b - Interlock cable nuts

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 Recoil Starter

4. Adjust the interlock cable nuts so the neutral interlock cable ball is centered on the
recoil lock.

22640

a - Neutral interlock cable ball b - Recoil lock

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Notes:

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