SECTION 10

Manual Starter

DESCRIPTION

This section provides information on the adskillelse, reparation and samling of the various types of Manual Starters used on Johnson Outboard Motors. It includes descriptions of how the different starters work and of specific details of their design and installation. All information relative to the removal and reinstallation of starters is furnished here; information on the removal of the power head starter assembly from the motor will be found in Section 5, eftersyn.

MANUAL STARTER

The Ready-Pull starter is comprised of a starter housing, rope and handle, pulley recoil spring, and a pawl or pawls which extend to engage the flywheel ratchet when the rope handle is pulled (see Figure 10-1). At the end of the stroke, the pawls retract and the spring rewinds the rope on the pulley as the starter handle is returned to the housing.

A starter lock-out arrangement (see Figure 10-2) is used on most models to avoid starting the motor while the gearshift is engaged and throttle is advanced beyond safe limits.

The Gear-Drive starter pinion gear engages a ring gear on the flywheel when the rope handle is pulled (see Figure 10-3). At the end of the stroke, the pinion gear is disengaged as the recoil spring winds the rope back on to the spool.

Ready-Pull Starter adskillelse

1. Remove the starter handle and allow the recoil spring to slowly unwind until the pulley stops revolving. Remove the spindle screw, washers, and pawl komponenter.
2. Carefully lift the pulley straight up out of the housing being careful not to .disturb the spring. To remove the spring, turn the housing spring side down and jar it against the bench top or floor.

Ready-Pull Starter samling

To install the recoil spring, two methods can be used. Motors below 40 HP allow the use of a Starter Spring Winder (Special Tool).

1. Motors of 40 HP and over, place the outside loop end of spring over the pin in the housing. Coil the spring counterclockwise inside the housing, one loop at a time. Bend the inside loop end of the spring into position to align with the anchor pin in the pulley (see Figure 10-4). Lubricate the recoil spring with OMC Type "A" lubricant.
2. Place the pulley in the housing making sure that the spring loop slips over the pulley anchor pin. Lubricate with OMC Type" A" and install the spindle. When installing the pawl or pawls, be sure the action causes them to extend outward when the pulley is rotated in a counterclockwise direction as viewed from the bottom (see Figure 10 - 5).
   
3. Wind the pulley counterclockwise against spring tension until tight. Allow pulley to unwind about one turn or until a locking pin can be slipped through the aligning holes in the pulley and housing. Lock the pulley to the housing with the pin (see Figure 10-6).
4. If installing a new rope, be sure it is cut to specified length. Some models use an elliptical rewind pulley timed to provide greater torque on the piston compression stroke. Rope length governs the timing of the pulley to the piston.
5. Singe both ends of a new rope to a length of 1/2 inch to fuse the nylon fibers. The rope ends must be stiff to hold properly in the pulley and rope anchor.
6. Tie a knot in the rope and thread the rope through the hole in the pulley and the guide hole in the housing. Lubricate the handle end of the rope, and install the rope handle using a Rope Threading Tool (Special Tool). Lay the rope into the channel in the rope anchor with the stiff end of the rope butted against the end of the channel. Press the anchor into the handle. Remove the pin and allow the pulley to recoil slowly.
7. Starters with elliptical rewind pulleys have timing marks on the pulley and housing (see Figure 10-5). When the starter handle is at rest against the starter housing, the timing marks should be aligned. NOTE: If the timing marks indicate that a new rope is slightly short, this will correct itself. New ropes tend to stretch with use.

Gear-drive Starter adskillelse

Remove the starter as described in Section 5, eftersyn. Remove the roll pin retaining the pinion gear, bearing head, and mainspring retainer. Pull the mainspring assembly from the spool. Remove setscrew (9-1/2 HP only) to remove lower spring retainer, bushing, and outer bearing from spring.

Gear-drive Starter samling

1. Place the upper bushing and starter head with the pinion gear spring, on the starter spool. Insert the spring retainer in the spool. Place the pinion gear on the spool. Align the slot in the gear with the holes in the spool and spring retainer. Insert the roll pin with its split seam in a horizontal position (see Figure 10-8). This will avoid dragging the split against the slot in the pinion gear. NOTE: DO NOT lubricate the pinion gear or spool. Oil or grease will attract dirt causing the pinion to bind on the spool.
2. Lubricate the starter mainspring with a light coat of OMC Type "A" lubricant and inset into the bottom of the spool. Twisting it will engage it at the end of the spring retainer.

samling to Power Head

Place the bushing in the starter plate. Pull the free end of the mainspring out of the spool. Attach the hook on the free end of the spring by twisting to engage in the slot in the spring retainer plate (see figure 10-10). Place the guide in the starter plate. Attach the starter to power head.

Rope Installation

1. Place a heavy duty screwdriver or brace with a screwdriver bit in the slot on the top of the starter spool (see Figure 10-11). Wind the mainspring counter­clockwise 16-1/2 turns (5 HP). The rope anchor hole in the spool should face the port side of the power head.
2. Raise the pinion gear to engage the flywheel and lock it in position with the handle of a pair of pliers (see Figure 10-12). If a new rope is being installed, be sure it has been cut to the proper length (66-3/4 inch for 5 HP) and the ends fused for a length of 1/2 inch to prevent unraveling. The ends must be stiff to hold in the spool or rope anchor. Form a short loop in one end of the 5 or 6 HP rope. Insert the loop through the eye in the spool (from the aft side to the front). Bring the short end down under the eye and thread up through the loop (see Figure 10-13). Tighten the loop and keep the end of the rope against the spool to prevent snagging on the guide. Install the starter handle.
3. Hold the starter rope handle and remove the pliers from under the starter pinion gear. Allow the starter rope to rewind slowly.

rensning, inspektion, and reparation

Wash metal komponenter in solvent such as Solvasol and dry with compressed air. Inspect the recoil spring for breaks and weak tension. Inspect the pawls, or pinion gear, and other komponenter for wear and fractures. If the rope is frayed, replace it. If excessive rope wear is observed, look for sharp or rough edges in the pulley or housing. Remove sharp or rough areas by filing and polishing.