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Repair instructions
WARNING!
If the recoil spring is still under
tension when the pulley is re-
moved it can fly out and cause in-
jury. Wear eye protection.
Starter assembly – removal
1
Undo the four bolts that fasten the starter assembly
to the crankcase and lift off the starter assembly.
2
Pull out about 30 cm of the cord and fasten it in the
notch in the pulley rim. Release the tension in the
return spring by letting the pulley wind backwards
slowly.
3
Remove the bolt from the centre of the pulley and
lift off the pulley.
Cleaning and inspection
Clean the parts and check the following:
• The starter cord.
• The teeth on the pulley, lubricate with oil.
• That the pawls on the flywheel are undamaged,
i.e. that they spring back towards the centre and
move freely.
• Lubricate the return spring with light oil.
Replacing a broken or worn starter cord
1
Before replacing a worn starter cord the tension in the
recoil spring must be released. Pull the starter cord out
through the notch in the pulley rim and wind the pulley
anti-clockwise to release the tension in the spring.
2
Remove the bolt from the centre of the pulley and
lift off the pulley.
3
Fit a new cord through the hole in the pulley and tie
a knot to secure it. Feed the other end of the cord
through the hole in the starter housing and through
the starter handle, then tie a double knot in the
end. Wind about 3 turns of the starter cord onto the
pulley. Fit the bolt through the centre of the pulley
and tighten to a torque of 2–3 Nm.