How-To: Repairing Your Pullstart - Pocket Bike Forum - Mini Bikes
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post #1 of 36 (permalink) Old 01-22-2009 Thread Starter
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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!

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post #2 of 36 (permalink) Old 01-23-2009
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Thumbs up Re: How-To: Repairing Your Pullstart

Holy Cow! That is an awesome description of how to do that task. You should make some more how-to's! Great Job!! SpyGuy.

Wish I knew as much as you about Pocket Bikes!

Thanks Again SpyGuy!

Curtis
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post #3 of 36 (permalink) Old 01-23-2009 Thread Starter
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Re: How-To: Repairing Your Pullstart

Just takes lots of reading and experimenting .... plus a decent stash of spare parts.

Can one of the admins please sticky this, or move it to the A/C How-To section? thank you.

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post #4 of 36 (permalink) Old 01-26-2009
 
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Re: How-To: Repairing Your Pullstart

Awesome post.
I figured it the hard way. I tried winding it in my hand atleast 100 times, bla bla bla. if what your trying to do is not working, thenn you have to try a different approach. Great post.
Should be very helpful to a lot of people.
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post #5 of 36 (permalink) Old 02-19-2010
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Re: How-To: Repairing Your Pullstart

Hi There Spyguy And Others I Need Some Help I Broke The Handle On The Pull Starat But I But It Back Toghter But Now When I Pull The Pull Cord It Gets Stoke Quator Way Throw Like The Claw Gets Stoke Out And The Cord Gets Stuck Too Help Me Please its the claw beacuse when i pull the cord and keep pushing the claw in it comes out all the way but when the claw comeout it get stuck wide open !!!!!!!!!!!!!!!!help


Please Help Me

Last edited by mickey110; 02-19-2010 at 11:09 AM.
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post #6 of 36 (permalink) Old 03-02-2010
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Re: How-To: Repairing Your Pullstart

lol i had the same thing happen to me one day, but i couldnt get that **** thing back together, for the life of me. i had some ohere guy do it for me.
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post #7 of 36 (permalink) Old 04-18-2010
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Re: How-To: Repairing Your Pullstart

how about a video?
im having trouble following the last part which i really need.
i would HIGHLY appreciate it

Last edited by DaillestXL; 04-18-2010 at 01:43 PM.
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post #8 of 36 (permalink) Old 04-27-2010 Thread Starter
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Re: How-To: Repairing Your Pullstart

Quote:
Originally Posted by DaillestXL View Post
how about a video?
im having trouble following the last part which i really need.
i would HIGHLY appreciate it
Sure ... get me a video camera, and I'll do one for you.

What part are you having trouble with? Putting the rope in the pullstart? The rope threads down through the top of the pullstart, and out through the hole in the case. The knot in the rope will catch the edges of the hole - being too big to go through - and then you start winding up the rope on the reel.

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post #9 of 36 (permalink) Old 06-12-2010
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Re: How-To: Repairing Your Pullstart

Hi,

Ive just joined the site i have a 49cc pocket-bike dunno what brand, but me and a mate were using it yesterday and as it hasn't been used for a while as we moved house and it has been a very cold long winter it started (eventually) and we had to take the rear wheel off etc, as it was punctured and now is back together but the pull-start cord has come all the way out when we tried to start it and wont go back in, normally it recoils but now it suddenly wont. can i fix it by following the guide by spy guy??

i am fairly able mechanically given enough time so should hopefully be able to find it, as really want to get the bike going for summer as it fits perfectly in the back of my car...

all help appreciated!!!!

Last edited by Giggity21; 06-12-2010 at 05:05 AM.
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post #10 of 36 (permalink) Old 06-12-2010 Thread Starter
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Re: How-To: Repairing Your Pullstart

Yah, just follow the instructions and you should be fine. Now, if the pullstart jams when you go to pull it, there may be a bigger problem ..... try spinning the flywheel by hand while you have the pullstart off the bike,.

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Re: How-To: Repairing Your Pullstart

I, just joined this website i have a Gio F2 pocket bike and the pullstart wont pull and i took it all apart and it still dont work ?
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post #12 of 36 (permalink) Old 08-21-2010 Thread Starter
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Re: How-To: Repairing Your Pullstart

Does the pullstart jam? Try turning the flywheel by hand first. If it doesn't turn, you may have bigger issues than just a broken pullstart.

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Re: How-To: Repairing Your Pullstart

The pull start isnt broken it just wont pull out everytime i pull it its hits somthing and wont come out
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Re: How-To: Repairing Your Pullstart

its like the pull start wont pull the fly wheel.
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Re: How-To: Repairing Your Pullstart

Well like spyguy said can you spin your flywheel by hand because it might not have anything to do with the pullstart.
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I've got it recoiled. Rope retracts all the way. But the motor still won't start. Any ideas??? Please help!
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Re: How-To: Repairing Your Pullstart

I have a 49cc quad Which is my sons my brother though he'd start it 1 day and he was pulling the cord like a mad man and something happened ! Anyway i tried to start it the other day and it Wouldn't start you can feel it wanting to start but half way pulling the cord its like somethings broken so i taken the case off the front of flywheel and the 2 springs that go around the 2 arms are loose has that anything to do with it ????
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Re: How-To: Repairing Your Pullstart

Sounds like something is bad in the pull start housing. Is it a plastic housing or alum?? The arms have springs to hold them in the start position, once the engine starts they are flung out of the way. Have you tried putting a little gas down the carb to see if it fires up?? The 2 biggest problems on that engine are, main jet is clogged, that can happen sitting to long stored and gas can't get thru, or you have a bad coil. Pull the spark plug, and with the wire on, ground the outer nut of the plug and pull the rope fast to see if you have a spark, but your pull start might be broken. Online you can find just the rope housing part and bolt it to your old alum housing about $10. Take the float bowl off the bottom of the carb and remove the brass main jet and clean it good, cleaner and a small wire.

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Re: How-To: Repairing Your Pullstart

my pull start pulls easy and spins the flywheel but it wont catch or fire off at all its gas powered. please help
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Re: How-To: Repairing Your Pullstart

Quote:
Originally Posted by evilangelizzie View Post
my pull start pulls easy and spins the flywheel but it wont catch or fire off at all its gas powered. please help
Sounds like you may have a loose or broken flywheel and needs to be fixed or you need a new coil..

Your problem description isnt the greatest at giving a dead-on answer

Do you hear the engine making a thump thump noise and do you feel any kind of compression feedback?

You may need a new topend,,new reeds,,,is the sparkplug in the hole?

Pictures of the bike in question would be very helpful in helping you better...

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Last edited by CAM2; 04-08-2018 at 07:56 PM.
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