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Most likely the reason for the jamming of pull rope would be the rewind coil was over stressed due to use and age (they become brittle after a while) and where the coil catches on inside of housing snapped causing a slight unwinding and then the restricted movement of pull rope assembly. If you have it apart you should be able to see where the coil connects at both ends and attaches to its mating location. If you do not see the typical bent coil hook then your coil is broken. No worries, if this is the case, heat the broken end with a lighter or torch and use a pair of needle nose pliers and reshape to match the hooking location. Once completed, rewind coil and place masking tape around coil temporarily holding coil in place and leave yourself about three inch lead of coil to attach where it needs to go. Insert and fasten coil assembly then remove all pieces of tape. At this time your pull rope should be recoiling and rewinding pull rope. Always wear eye protection.
New or used unit? If new can you return it ? If not you will need to take the recoil assembly off the engine and rewind the spring. Check inside the recoil assembly to see if the spring is broken or just popped out of place on either end. If it is broken your done. You will need to find a Poulan dealer to get a new spring. If new take it to a Poulan dealer for warrenty replacement. If you want to try to rewind the spring look to see where one end of the spring fits into the housing and the other into the spool. On the edge of the puley should be a notch. Place the rope in the notch and turn the pulley it in the direction needed to wind the spring about 4 or 5 turns. If it now pulls all the rope in you are done.If not put the rope back in the notch and wind the spring tighter till the rope is all pulled in.
I'm going to assume you have a new rope. If you look at the rewind pulley (plastic disc) there should be a hole where the original rope went through. Run the rope through this hole and then through the hole in the starter housing itself. At the other end of the rope near the pulley, tie a knot at the end of the rope and pull it through the housing until your new knot is up against the hole in pulley. Next put the rope through the starter handle and tie another knot. Now you should have a rope with a knot on both ends with the handle near one, and the pulley on the other end. Now if you look at the pulley on the outer edges, you will see a notch in it. Hold the rope into that notch and spin the pulley in a clockwise rotation for about four turns. Don't let go of pulley because there will be tension on the spring. Hold pulley with your thumb while pulling rope out of housing on the handle side until taught. Hold rope outside of housing and release pulley. Now slowly release rope on handle side of housing an let it slide back around pulley. When tension is released and if there is still rope hanging out of starter housing, repeat the above steps but instead of going four turns around with rope in notch, only go one at a time until the handle is all the way back to housing. It's important not to go too many times with your wrap around because it will cause spring to be too tight which may cause breakage in the future....Just go far enough to let handle touch the housing and you should be good to go.
This would be much easier to show in a video than in type. I hope this helps.
Was the saw dropped on it's left side? Remove the entire starter housing and look for bent metal parts. Does the cord operate normally when off of the saw? Unless the housing was crushed, usually you can bend some of the internal metal parts to get the spool to turn freely. Hope this helps!
If the spring is unwound. Recoil Spring Rewind I invert and secure the starter housing and rewind the spring large coil to small (need eye protection and both hands). I am right handed so I tension the spring enough to insert it inside the previous coil while holding what has already been installed with my left about 180° from my right hand. The tension will hold the spring in the housing once completely rewound. Then bend slightly the inner most part to engage the starter spool. It will require about 2 turns of pretension for it to retract properly. If the starter cord needs a pretension, this works quite well. R² Starter Rope by SmallEng.com http://www.youtube.com/watch?v=eRyy3MlsjVo If you have more questions or need additional help please reply below and I will get back to you. Thank you for using FixYa and Good Luck. HTH Lou
this can be caused by sevral things inside the pull cord hub assembly. examples: Dirty inside & needs taken apart & cleaned. something logged inside, plastic spool tabs broke, spring/s broke, levers broke or any of these items could just be to worn. replacement parts should be available.
Recoil Spring Rewind I invert and secure the housing and rewind the spring large coil to small (need eye protection, both hands and no women around work area!). I'm right handed so I tension the spring enough to insert it inside the previous coil while holding what has already been installed with my left about 180° from my right hand. The tension will hold the spring in the housing once completely inserted. Then bend slightly the inner most part to engage the starter spool. It will require about 2 turns of pretension for it to retract properly. If you're lucky you can pull the cord out enough for a pretension then slightly raise and add the withdrawn cord to the spool. HTH Lou
as you put the side with the recoil starter back on the saw, ensure the rewind pack isn't binding. before tightening the screws, pull the rope out a few inches and let it rewind. if it won't, something is binding. keep moving the side panel till it will rewind. I have done this before myself. get it all put back together and it won't work.....