How to pull clutch assembly to replace pull start rope

Very fun job Not. Very involved and time consuming.

First your should be about 3 long some unit uses slight longer ropes and it is probably a number 3-1/2 rope.

1. Need you to separate the upper drive assembly from the engine assembly. You may to disconnect the throttle cable and the ignition kill wiring.
2. Remove the clutch cover.
3. Disconnect and remove the spark plug.
4. Install a piston stop in place of the spark plug.
5. Remove the clutch drum. Has small screw in center; usually has a Trox head on it.
6. Remove the clutch assembly. Usually has left handed threads so turn it clockwise.
7. Once the clutch is removed then you need remove the starter cover assembly and the air cleaner cover assembly.
8. Once the starter cover assembly is off remove the pull rope pulley and check for damage.
9. Depending the pulley design you can now install a new rope first or you need to re install the pulley.
10. Tighten the pulley fully by turning the direction as you would pull it until it stops and back off one turn.
11. If the pull rope hasn't already been install install it now. Otherwise make you have the pull handle on the rope and release the pulley tension slowly until the rope is tight.
12. Now re-assemble everything in reverse order.

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.

The pull rope clutch or pawn may be broken.

Take rope assembly off to see what is broken.

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.

Sounds like the starter dogs are broken. They are little plastic teeth that engage to turn the engine when you pull the cord. You'll need to replace the whole starter assembly to fix this.

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!

Good luck on finding a manual. You can get the exploded parts drawing off of the sears parts website! I have a 32cc model 358.791580 and the pull rope broke. The pull rope assembly is located inside of the motor housing. I am having trouble removing the clutch assembly since there is no key way or screw holding it to the shaft. Does anyone know if it is threaded on?

sounds like you are trying to remove the drum assembly; try a torx driver or a phillips screwdriver. There is a srew that hold that drum on and the bolt is in that black hole.

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.