Power Unit [Recoil Starter] [2002]

Step	Procedure/Part name	Q'ty	Service points
	RECOIL STARTER REMOVAL		Follow the left "Step" for removal.
1	Lock nut	1
2	Start-in-gear protection wire	1	NOTE:
			Disconnect the wire at the bottom cowling side.
3	Bolt (with washer)	3	6 x 35 mm
4	Recoil starter ass'y	1
5	Dowel pin	1
	RECOIL STARTER DISASSEMBLY
(1)	Start-in-gear protection wire	1
(2)	Spring	1
(3)	Starter stopping plunger	1
(4)	Circlip	1
(5)	Drive pawl	1
(6)	Drive pawl spring	1
(7)	Bolt (with washer)	1	6 x 30 mm
(8)	Stay	1
(9)	Rope roller	1
(10)	Collar	1
(11)	Nut	1
(12)	Bolt (with washer)	2	6x12 mm
(13)	Nut	1
(14)	Bolt (with washer)	1	6x 20 mm
(15)	Plane washer	1
(16)	Bushing	1
(17)	Sheave drum	1
(18)	Spiral spring	1	NOTE:
			* When installing the new spiral spring,
			do not cut the wire holding the spring.
			* When reusing the spiral spring, set the
			leading end first in the case and then fit one turn each time.
(19)	Starter case	1
(20)	Cover	1
(21)	tarter handle	1
(22)	Damper	1
(23)	Seal	1
(24)	Rope guide	1
(25)	Rope	1	2,095 mm
			Reverse the removal steps for installation.

Sheave drum removal

1. Turn:

• Sheave drum (1)

  Turn the sheave drum clockwise until the spiral spring is free.

NOTE:

• Turn the sheave drum so that the cutaway on the outer surface of the sheave drum faces toward the starter handle.

• Pass the starter rope through the cut.

2. Remove:

• Sheave drum (1)

WARNING

When removing the sheave drum, be sure to turn the sheave drum upside down to prevent the spiral spring from popping up at you.

NOTE:

Insert a slotted-head screwdriver into the hole in the sheave drum, and remove the spiral spring from the sheave drum by pushing the spring.

Spiral spring removal

1. Remove:

• Spiral spring (1)

WARNING

Be careful so that the spiral spring does not pop out when removing it.

Remove it by allowing it out one turn of the winding each time.

Starter stopping plunger inspection

1. Inspect:

• Starter stopping plunger

  Crack/Wear/Damage -> Replace.

Drive pawl and spring inspection

1. Inspect:

• Drive pawl

  Crack/Wear/Damage -> Replace.

• Drive pawl spring

  Broken/Bent/Damage -> Replace.

Rope roller and collar inspection

1. Inspect:

• Rope roller

• Collar

  Crack/Wear/Damage -> Replace them as a set.

Bushing inspection

1. Inspect:

• Bushing

  Crack/Damage -> Replace.

Sheave drum inspection

1. Inspect:

• Sheave drum

  Crack/Damage -» Replace.

Spiral spring inspection

1. Inspect:

• Spiral spring

  Broken/Bent/Damage —» Replace.

Starter rope inspection

1. Inspect:

• Starter rope

  Fray/Wear/Damage -> Replace.

NOTE:

When replacing the rope, cut it to the specified length and burn the rope end so that it will not travel.

Starter rope length: 2,095 mm (82.5 in)

Starter rope installation

1. Install:

• Starter rope

NOTE:

• Insert the rope through the rope holes and knot the end.

• Wind the rope 1-9/10 turns around the sheave drum.

• Place the rope at the cutaway.

Sheave drum installation

1. Install:

• Sheave drum (1)

NOTE:

Position the inner end of the spiral spring on the retainer post of the sheave drum.

Spiral spring setting

1. Set:

• Spiral spring

NOTE:

Wind up the spring 2-1/2 turns counter clockwise with the starter rope.

Recoil starter checking

1. Check:

• Starter operation

  Unsmooth operation -» Repair.