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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.
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!
Most commonly, the recoil rope rewind spring is broken. However, inspect the recoil housing assembly first to make sure no debris or rope fragments have prevented the rope rotor from rewinding. Always remove the spring 'AS A LAST RESORT'. Many rewind problems can be solved by inspection of the rotor and not have to remove the spring. In case you do, I will include instructions on how to re-install.
1) remove the recoil housing
**NOTE: normally you DO NOT need to remove the rotor pulley or spring to replace the rope. This is the area that causes so many guys a lot of extra trouble
2) locate the string that is left and the hole it is threaded thru
3) determine how much string has broken off of the rope that came out
Note: if more than 1 inch is left, then the rope needs to be replaced
4) after rope is obtained, make sure both ends are melted to a point for easier threading thru handle and rope rotor
5) install the rope (with the handle installed on one end) thru the recoil housing and towards the rope rotor.
6) with the rotor free of tension, route the rope from the groove toward center and up thru the hole. Tie a knot in the end of the rope, leaving a 3/8" tail free.
7) wind the rotor in the direction of what the rope would pull (this will tighten the spring) until the spring is completely wound. remove 1/2 to 1 revolution, and then allow rope to wind onto the rotor until all rope is wound.
8) Pull the rope several times to position rope properly into rotor.
*note : there should be NO droop in the handle after released
If droop is evident, wind the rotor and rope 1 revolution tighter so there is no droop of handle when released
9) when unit is functioning proplerly, re-install housing onto unit
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