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Replacing manual starter rope or spring on a 9.5 hp outboard motor

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SOURCE: evinrude outboard motor starter rope

most likly is missing a washer,has been reassembled incorrectly.take apart and check

Posted on May 08, 2009

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1974 40H.P. mercury outboard been setting up for 10to12yrs


This is probably a Merc 400 and you can remove the upper cowling and rope start it if you do not have the rope starter already attached. As I recall, all of this class motor were manual start with optional electric start, so thy came equipped with pull starters.

If the motor will not turn over manually then it is likely seized or frozen up and requires professional help. I have worked on numerous Mercs from 5 to over 100 HP and every one would turn over by pull starting if they were mechanically sound.

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Starter cord will not pull


The pull cord or rope works on a tight spring just under the cover that the rope is in. Usually three to four small bolts on the edge of the cover to remove to repair/replace either the spring or the rope. First I would try to turn the motor manually with your hand on the flywheel, it should move around either direction freely with no effort. If it does not the motor itself maybe stuck not the rope. Then you have a seized engine and a different problem to deal with.

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1 Answer

Starter rope replacement


recoil spring has slipped out of the hole.pull your starter rope out of the wind up mechanism, insert the spring latch on both ends and put back into housing. with a piece of 3/4 square stock or something the will fit mthe hole start to wind the mechanism spring up tight. with apair vishgrips lock it down so it does not move. insert your starter rope anr release the visegrips. the springwii recoil and pull the rope in.cut off excess rope. good luck

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1 Answer

15 hp crysler outboard motor pull start diagram


You will need a special tool to do that job. It is just a 10/24 long bolt bent to form a crank and a nut spun on it and soldered or double nutted to keep it in place.

Remove the top slotted bolt and replace it with the tool.

Release the pressure on the cross pin by back winding the spring- and remove the cross pin.

The starter gear will slide up the shaft after you remove the flywheel. Or you can loosen the 2 screws on the top bracket.

Now release the tension on the spring and pull the core from the spool.

The spool comes out and the rope must be freed from the guide.

The reverse is about the same- feed the cord and spool it up attach the handle.

Replace the top bracket if you removed it. Put on the starter gear

grease the spring with light grease inspect the nylon base and coil anchor (tiny brass cinch squeezed on to the stub of spring coming from the base.

Now -with the tool- wind the spring backward about 5 times and insert the pin thru the gear and into the shaft. With the tool in place pull the starter thru several times to see if the tension is right and you didn't forget the rope guide..

Replace the original screw to hold the pin in place.

This works for most pop-up starters.

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1 Answer

How to install recoil start roap on 6 hp johnson outboart


put recoil assy in a vice with several turns on the spring and clamp so you can see the area where rope fits in and fit rope and route with handle on then carefully release from vice !

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1 Answer

Ryobi string trimmer RY34420 has a non retracting pull cord. How do I fix it?


The starter assembly is between the motor and boom so you have to remove the boom from the motor housing. Usually one nut & bolt at the nose of the starter housing. There may be another lock bolt. You shouldn't have to remove the throttle cable and leads but it depends on how tight the factory installed them. Remove the starter housing. If you're real lucky all you have to do is pull some starter rope up past the pulley and wind the pulley in the direction the rope pulls back into the housing. You have to pull the rope around the pulley as you wind it. If the spring catches and builds tension you're good, wind it four or five times or enough to fully pull the rope back in. If the spring doesn't catch or releases every two or three turns it has to be replaced. You may have to replace the spring and container (PN638033001) and/or the easy start assembly (PN310022001).

Aug 31, 2010 | Ryobi Garden

2 Answers

Starter rope won't retract


You have to wind the spring as tight as you can before you put the rope on. Then allow the spring to unwind, pulling the rope onto the spool. Be very careful when you take it apart. Good luck...Lee

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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

Pull the rope all the way out and hold slight tension on the rope and release the tension on the pulley but still holding the starter housing

Starter spring should pull rope into housing... good luck

Sep 08, 2009 | Garden

1 Answer

Starter cord broke went to replace cord and spring came out. how do you rewind and reinstall spring and cord. have lots of tools


Best thing to do is replace the starter rope, if you don't, you're asking for trouble. Get the right length of rope, don't use a longer rope than recommended or you could wrap the spring too tight when you start the motor. I always replace the spring too. It's cheaper than trying to wind up the old one and get it back in. Good luck.

Jun 13, 2009 | Garden

1 Answer

Evinrude outboard motor starter rope


most likly is missing a washer,has been reassembled incorrectly.take apart and check

May 06, 2009 | Boating

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