Starter cable housing assembly

Replace the fan assemblies.

Although it looks like you simply un-bolt the recoil starter you need remove the whole blower (flywheel) housing as there are nuts on the back side.

• Once the housing is off, remove the broken rope and prepare a length of rope to replace it base upon the old ropes length. Probably close to 6 feet.Don't forget to put the pull handle on the new rope.
• Tighten the recoil pulley in the direction it normally turns as you pull the rope out until it stops.
• Slowly back of up to one turn to align the hole in the pulley with the housing hole and hold it in that position while you insert the rope and try a sturdy knot.
• Slowly let recoil assembly pull the rope back in and test that it is working properly before re-installing the housing.
• Once you are satisfied that the recoil is working properly re-install the remaining covers.

According with the repairt guide, check this porocedure to REMOVAL & INSTALLATION

1. Disconnect the cable from the negative terminal of the battery.

Fig. Exploded view of the starter motor mounting - 5S-FE engine shown, others similar (click image for zoom)

1. On some early models with cruise control, you may have to remove the battery.
2. Also on some models with cruise control, remove the actuator cover and disconnect the wiring harness. Remove the three bolts and then lift out the cruise control actuator. Remove the bracket from beneath the actuator and put aside.
3. Peel the rubber boot away and remove the nut and disconnect the negative battery cable from the magnetic switch terminal on the starter. Disconnect the electrical connector also located on the magnetic switch.
4. Support the starter by hand and remove the two mounting bolts.
5. Remove the starter from the transaxle.

To install:

1. Place the starter motor in the transaxle and support by hand.
   
2. Install the two mounting bolts and tighten them to 29-31 ft. lbs. (39-42 Nm).
   
3. Connect the connector to the magnetic switch. Place the battery cable on the switch terminal and install the nut. Tighten the nut and position the rubber boot over the cable.
   
4. Using the ignition switch, "bump" the starter over a few times and check for proper operation.

SOLENOID OR RELAY REPLACEMENT
The starter solenoid (magnetic switch) is an integral part of the starter assembly.

1. Remove the starter from the car. Remove the heat insulator from the starter assembly, if equipped.
   
2. Disconnect the wire lead from the magnetic switch terminal.
   
3. Remove the two long, through bolts holding the field frame to the magnetic switch. Pull out the field frame with the armature from the magnetic switch.
   
4. On 1.0 kW starters, remove the felt seal. On 1.4 kW starters, remove the O-ring.
   
5. To remove the starter housing from the magnetic switch assembly:
   
1. On 1.0 kW starters, remove the two screws and the starter housing with the idler gear and clutch assembly.
   
2. On 1.4 kW units, remove the two screws and the starter housing with the pinion gear, idler and clutch assembly.

To install:

1. If necessary, install the gears and clutch assembly to the starter housing. Apply grease to the gear and clutch assemblies and:
   
1. On 1.0 kW starters, place the clutch assembly, idler gear and bearing in the starter housing.
   
2. On 1.4 kW starters, place the clutch assembly, idler gear, bearing and pinion gear in the starter housing.


2. Insert the spring into the clutch shaft hole and place the starter housing onto the magnetic switch. Install the two screws.
3. On 1.0 kW units, install the felt seal on the armature shaft. On 1.4 kW units, install the O-ring on the field frame.
   
4. Install the field frame with the armature onto the magnetic switch assembly and install the two through bolts.

NOTE There is a protrusion or tab on each part; make sure you line them up correctly.

1. Connect the wire to the terminal on the magnetic switch. Install the heat insulator, if equipped.
   
2. Reinstall the starter on the vehicle. Check starter system for proper operation.

Hope this helps (remember to rating and leave a testimonial comment about this answer).

Follow the positive battery cable to the starter solenoid. Take a wire and jump the two posts on the solenoid or touch the two cables together. If your starter works, then you need a new solenoid. If you hold the starter button and tap on the starter with a plastic hammer and the starter works you need new starter brushes. Anything else wrong with the starter and you need to replace the starter assembly , the manufacturer does not make replacement parts for the starter.

Take a wire and jump the two posts on the solenoid or touch the two cables together. If your starter works, then you need a new solenoid. If you hold the starter button and tap on the starter with a plastic hammer and the starter works you need new starter brushes. Anything else wrong with the starter and you need to replace the starter assembly , the manufacturer does not make replacement parts for the starter.

Follow the positive battery cable to the starter solenoid. Unplug the two small wires going to the solenoid and use a voltage meter to see if you have continuity when you press the starter button. If you do not, clean the starter button or replace the switch assembly. If you jump the two cable terminals on the solenoid and the starter cranks, you have a bad solenoid. If you hold the starter button and tap the starter with a plastic hammer and the starter works, you need new starter brushes. Any other problem with the starter and you will need to buy a new assembly.

Follow the positive battery cable to the solenoid. With a piece of wire or a jumper cable clamp short across the two cable terminals. If the starter works you have a bad solenoid. If you hold the starter button and tap on the starter with a plastic hammer and the starter works , you need starter brushes. If anything else is wrong with the starter, parts are not available , replace the starter assembly.

Follow the positive cable to the solenoid. Short from the battery cable to the starter cable, if the starter works you have a bad solenoid. Hold the starter button and tap the starter with a plastic hammer, if the starter works you need new starter brushes. If anything else is wrong with the starter you need to replace the starter assembly, the separate parts are not available .

No, you just remove the radiator grill and the side marker light and the headlight housing bolts and it comes out. Not a real hard job and is Real straight forward. Good luck and have a good day.

this issue is known well with dysons to be honest you will continue to have this problem for as long as you have the vacuum. they use substandard plastic parts which break easy. You will have to replace the button and make sure there are no other broken pieces of plastic in the housing before putting it back together.