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Re: How do I pull the clutch assembly to replace the pull...
Remove the starter housing, usually only 3 or 4 bolts or screws. on the inside should be a large white or black wheel, hold the outer case with one hand and rotate the wheel counter-clockwise with the other as many times as can without force. on the inside of the wheel should be a small hole, rotate the wheel to line it up with rope guide hole on the outer case/housing. use a nail or small screwdriver to help hold in place. feed the start rope through the 2 holes and tie a knot at the end, single or double depending on the size of the hole. if the end of the rope is frayed, use lighter to melt and twist to a point to make it easier to handle. when reassembling you may need to jiggle the handle for realignment. it works on an inner spring coil tensioner system, so if the cable has no tension when rotated or doesn't recoil back, the starter assembly will need to be replaced.
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I have pulled out the spark plug and stuffed some rope into the cylinder. The piston will then not be able to travel the full distance and will keep the clutch from turning. Use rope that will not shed particles. This will let you remove the clutch bell.
Pull out the spark plug and stuff some rope in the cylinder. This will stop the piston from moving allowing the nut to be loosened. Now you can remove and replace the clutch assembly. Use rope that is not going to shed particals inside the cylinder.
Here are the detailed instructions on how to fix this.
Remove the tube that holds the flex-drive shaft from the front of the motor cover.Remove the rear engine cover. Remove the throttle cable from the carburetor. Mark and unplug any wires for the on/off switch that go to the ignition coil (underneath front cover) if possible. Now if you have pulled the driveshaft tube out of the way, the clutch drum is up next. Inside it, screwed into the very end of the engine's crankshaft is a Torx #25 screw. Before you loosen it, you will have to lock up the engine. To do so, remove the spark plug. Pull on the starter until the piston is down, then insert a length of clean, soft rope into the engine. The engine will come up and compress the rope, thus locking it in place to allow clutch drum and clutch removal. Loosen the T-25 (Star bit or Torx head) screw inside the drum.. You may be able to remove it with a long thin-blade screwdriver also.It probably won't come completely out...it is made this way. Next, remove the clutch. It is screwed onto a small threaded section of the crankshaft Removal is counterclockwise.. It will be pretty tight. To help, apply peneterating oil. Whack the ears of the clutch near the center with a hammer and a dull flat-blade chisel or a small piece of wood unless there are bolts. then use a wrench. It will turn counterclockwise for removal and there will probably be a removal direction arrow on it's face. After getting that off, remove the Torx screws holding the cover to the engine. The starter unit should be mounted inside as it mates with the top of the flywheel to start the motor. Remember to preload tension (5-7 turns) on the starter unit. Make sure the handle is installed. Jam the unit with a screwdriver or vise grips so you can insert and tie off the new rope. Then remove jam device and let recoil pull your new rope into place while holding the handle. Reassemble and you are done. Disassembly requires Torx head drivers and a good flat-blade screwdriver. Post back if needed.
For a reasonable handy mechanic it is an easy job. What you have to do is expose the winder/clutch assembly and re-knot the end of the rope through the spindle and preload some spring pressure on the rope winder/clutch. You have to judge how much pretension to put on the winder so as to keep the rope wound and not too much that the rope snaps back uncontrollable.
You will need to lock down the cylinder to remove the clutch. This is not an easy repair. Remove the spark plug and lower the piston. Take a piece of small rope (the broken one works fine) and fill the cylinder with the rope. Raise the piston to "lock the cylinder. The clutch drum can now be removed by inserting a T15 or T20 torx into the center and turn the screw counter-clockwise. Then take a pair of large slip-joint pliers and turn the clutch assembly counter-clockwise to remove. Make note of what order all the little washers come off. Also, make sure to remove the clutch as an assembly...it is very difficult to put back together. When reinstalling the clutch, it is VERY important to get it tight. Failure to get the clutch tight will result in major engine damage. Make sure you replace the rope with 40" of #3.5 braided rope. Melt the ends of the rope so it doesn't fray and use a figure 8 knot to secure. Good luck!
you can get a pull rope at wal-mart.measure the belt and any parts store or place that sells lawnmower belts should have one.if the rope broke close to the end knot just pull the end knot with some needle nose pliers.once you have all the old rope out lay the old rope pieces on the ground and cut the new rope to match it as far as length.turn the pulley that the pull rope goes in six turns counerclockwise.then turn the slot the knot was in to the hole the pullrope goes thru and fish it thru then pull it up and out with apaiar of needlnose have someone hold the pulley until you tie a small knot in the end of the pullrope the hold the pullrope and let it pull it in.you might have to cut some off at the handle if its still too long.to do this pull some rope out and tie a quick knot so the rope can't slip back if you let it go.
ther eshoul dbe some bolt holding the pullcord/recoil assenbly to the flywheel/motor. you need to locate and find these bolts first. let me know when you have this apart. you have to unwind the rope and pull it completley out, then buy a new pullcord rope(other rope will just fray and break agai) slip it thru the holes tie a knot wind up the spring and carefu;lly place it back on were it came. let me know if you run into any trouble.