Each time you pull start your mower, the nylon braided wire is rubbed against the round and smooth splint on the side of the starter coil. This constant friction makes the rope wear out and finally break. Since it only takes a few minutes to adapt to a new cable, removing the recoil starter and winding a new rope around the pulley at the first sign of wear, it is easier to replace a frayed rope than to excavate the jammed debris from the pulley des Then the rope fits.
Instructions
1 Loosen the three or four 1/4-inch bolts that hold the starter coil to the motor with a socket wrench, and place the unit in inverted position on your workbench.
2 cut the cable just below the starter handle with a pair of side cutters and unwind the wire around the pulley. Grasp the knot protruding from the pulley flange with a pair of pliers, and pull the worn rope out of the starter motor.
3 Feed a new rope through the starter handle. Tie an eight knot around the end of the cable protruding through the back of the handle and cut the rope about an inch from the knot. Hold the handle with one hand and give the rope a couple of pulls to tighten the knot.
4 Relax the pulley around half a turn counterclockwise against the return spring tension until the flange hole in the pulley lines aligns with the ferrule on the side of the casing. Keep the pulley with your thumb and feed the new cable through the splint and up through the hole in the pulley flange.
5 Tie a single knot on the end of the cable. Pull the protruding rope out of the splint, and give it a couple of pulls to tighten the simple knot on the pulley. The ease of the rope to allow the pulley, to close the clock needles again around half a turn until it stops.
6 cut the cord about 3/8 inches from the knot and seal the end by melting with a lighter or phosphorus to prevent frayinging.
7 Hook a folded paper clip around the rope between the splint and the pulley. Pull the rope up to form a loop between the pulley and the inside edge of the casing, until the handle rests on the side of the casing. Rest the pulley a bit to align the notch on the upper outer edge of the pulley, about an inch before the splint arrives.
8 Insert the end of the rope pulley into the notch on the edge of the pulley at the bottom. Roll the two-turn pulley anti-clockwise against the return spring tension until the rope engaged in the notch is just after the splint. Pull the starter handle to release the rope from the notch; Relieve the tension on the rope to allow the pulley to relax and draw the handle to the side of the casing.
9 Check that the rope has removed the starter handle all the way to the side of the back casing; If there is still some slack, repeat the previous step and the tension of the pulley to the left again, before pulling the free rope from the notch on the side of the pulley; This should point the handle to the bottom against the side of the casing.
10 Attach the starter coil to the motor with the screws removed above, and the test to start the mower to complete the installation.