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Starter Pulley Jammed

How do I replace a starter pulley spring on a P3416?

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A new spring can be found here:
Poulan.com
http://www.ordertree.com/modelinfo/POULAN-WEED-EATER/75.59.html

A new spring comes wound tight enough to be dropped into place in the starter housing (Easiest).

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 when inserted. It will require about 2 turns of pretension to retract properly.
If you're lucky you can pull the cord out enough for a pretension then slightly raise and wind the withdrawn cord onto the spool. GL
Lou

Posted on Sep 08, 2009

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The easiest way to do this is to wind the pulley up against the spring tention, when the pulley is wound enough, align the cord hole in the pulley up with the hole in the starter cover, knot one end of the new corc, feed the other end through the hole in the pulley and out through the hole in the starter cover, allow the pulley to rewind and pull the cord in, re connect the starter handle, if the rope doed not fully retract, hold the cord against the enge of the pulley and wind the pulley up against spring tention a further turn.

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There could be several reasons for this problem, but sometimes it is in need of a simple cleaning. Remove the 3-4 nuts holding the starter assembly on the top of the engine. Normally you will use a 10mm socket and ratchet to remove them. Turn the starter over in your hand so that you are looking at the starter pulley. Inspect the starter rope and make sure it isn't jammed between the starter pulley and the housing. If it is jammed, grab the starter rope and starter pulley and rotate them both together clockwise until the rope becomes unjammed. If the rope isn't jammed, turn the starter pulley counter clockwise gently. It will probably spring back and draw in the rope. If it retracts the rope slowly, spray WD40 around the bolt in the center of the pulley and work the pulley back and forth until the pulley frees up. If it doesn't free up or this isn't the problem, get back with me and I'll try and walk you through the rest of the repair.

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1 Answer

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  • 1

    Turn the Homelite chainsaw so that the bar and chain are laying flat and the starter cover is facing up. Loosen the four starter cover screws by unscrewing them counterclockwise with the screwdriver.

  • 2

    Take the starter cover off of the engine. Turn the starter cover over to work on the pull starter. Pull the rope out about 6 to 8 inches.

  • 3

    Twist a loop into the end of the rope. Insert the intersection of the two ropes into the notch on the upper flange of the pulley. Rotate the loop back and forth until you notice the recoil spring has disengaged. Unwind the rope from the pulley. Cut off any old rope if you need to replace it with a new rope.

  • 4

    Unscrew the screw holding the pulley to the starter cover using the screwdriver. Take the pulley off the starter cover. Turn the pulley over and remove the recoil spring cassette from inside the pulley.

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    Inspect the spring inside the cassette to see if it is damaged or overstretched. Replace the recoil spring cassette if it is broken. Lubricate the post on the starter cover using about a dime-sized amount of engine grease.

  • 6

    Put the recoil spring cassette back into the pulley. Set the pulley onto the starter cover and tighten the screw down with the screwdriver. Wind the starter rope back around the pulley in a clockwise direction.

  • 7

    Leave about 6 to 8 inches of rope unwound. Form another loop at the end and insert the loop into the notch on the pulley. Rotate the loop back and forth until you notice the tension is set on the recoil spring.

  • 8

    Remove the loop and place the starter cover back over the engine. Pull the rope out 6 inches and tighten the starter cover's screws using the screwdriver. Release the rope and it should automatically retract


  • hope this helps

    John

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    hi there

    csimonis

    it is quite likly that you could need a new pulley and spring

    but remove the cover and the starter assy 1st and check that the pawls have not stayed out or jammed , then try winding the spring and pulley up in the direction that the cord is moving when you pull the starter cord - check that end of the spring is still engaged onto the pulley , but if no tension is noted broken spring indicated

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    Hi b calm,
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    1 Answer

    Starter cord will not rewind after being replaced. The string will rewind in the housing before it is attached to the motor but not after being attached. How do you pre wind the springs?


    What I do is the following:

    Remove the old rope ( what is left of it)

    Wind the starter rope pulley about 8 or 9 complete revolutions after I am confident that the spring has engaged the starter pulley

    Hold the pulley in place ( align the rope hole in the pulley with hole in the starter housing

    Insert the rope and tie a knot, pull the rope back tight against the pulley

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