How-To: Repairing Your Pullstart
Okay, SO .... You just got home after a long day at work, and you pull the bike out to go for a ride. You gas it up, set the choke, turn on the petcock, grab the pullstart handle and give 'er a mighty heave - SNAP!!!!!!! The rope recoils back into the pullstart housing, and you're left looking at the handle in your hand (more than likely using some very creative language ...)
So you figure, "I can fix this, no problem." You whip out your Allen wrenches and yank that pullstart off, but you can't reach the end of the rope because of the lip on the reel. What do you do? "Hey, I'll just pull out that little bolt in the center where the starter pawl is," and...... KABLOOEY!!!!! The spring flies all over the place, usually to the accompaniment of more creative language. NOW what do you do? ......
Not to worry - got ya covered. Here's how to repair that broken pullstart.
-Take the handle off the rope. You want to only have one knot in one end of the rope. (Of course, if the rope's already broken, you can skip this step ....)
-Get the reel and lay it facedown.
-Get the coil, and begin carefully winding it up so that it fits inside the grooved edge on the reel. BE PATIENT - this will take time.
-On the inside of the coil, there should be a little hook on the end of the coil. That hook matches one inside the pullstart cover when you put the two pieces together. The trick is to get the hook on the reel to catch the hook on the pullstart cover. CAREFULLY put the reel and coil inside the cover, and screw the bolt in for a moment to hold it in place.
-Turn the pullstart reel clockwise until you feel the hooks catch each other. Feel some resistance? Good, that's what you want.
-Take the bolt back out, and reassemble the starter pawl assembly inside the pullstart, then put the bolt back in and tighten it.
You should now have a complete assembly, minus the pull rope. Okay, let's move on ....
-Now, looking down into the pullstart, notice there is a hole in the reel off to one side. This is where your rope threads through. Grab the reel, and crank it around about .... four or five times, and try to get the hole in the reel lined up as close as possible with the outer hole in the pullstart cover.
-Take your rope (you DID take the handle off first, right? Oh yeah, it broke off ...), and thread it through the reel, then through the outer hole in the cover. This will be a little tricky, as you need to be holding the reel so it doesn't unwind ...
-SLOWLY let the reel start to retract, but don't let it go all the way. Does it look like it's drawing the rope all the way back in? If so, great! If not, pull the rope back out, crank the reel around another turn, and try again.
-Once you have the reel set to where it will retract the rope all the way, thread on your handle and tie it off. You're done!
"I'm going off the rails on a crazy train." - Ozzy Osbourne
Dear haters: Please be patient. I have so much more for you to be annoyed about.