4206S rewind ***embly pull cord broke

[jrj2211]

Hey guys today I was firing up my engine (4hp 4206S) when I must have yanked the pull cord a little to hard as it came flying out (cord didn't break). Looks like something in the rewind ***embly is broken however because its not springing back away from the flywheel? My terminology might be incorrect here as I'm a sailor.

My main question is how do you rethread the pull cord in one of these? I tried to find the manual on Evinrudes website but couldn't so if someone has a digital copy that they could link me to that would be great. Also if someone has one of these motors and could take pictures on the rewind ***embly and pull cord that would really help.

Thanks!

EDIT: I find it funny that "as sembly" is a censored tag on here

[jrj2211]

I just took the rewind as-sembly apart and I found what broke. A little bit at the end snapped off of the spring. I figure since only 1/2 and inch broke off, theres plenty of coil left so I shouldnt have to buy any new parts. The center of the coil looks weird to me though with it not just all being in a circular path, is this how its supposed to be?

[Joe Reeves]

Depending on which type manual starter your engine has... I'm thinking the second one:

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(Manual Starter Cord Installation)
(This pertains to the vertical type of Manual Starters such as the 9.5hp and later 4.5/6/8hp models etc)
(J. Reeves)

1 - Have a pair of vice grips handy set so that they will grab the top of the starter spindle tightly but will not damage it.

2 - Using a large screwdriver inserted into the top of the starter spindle, wind the starter in a counter clockwise direction 12 to 14 turns, stopping so that the cord locking slot is facing the away from the engine.

3 - Lock the spindle in that position with the vice grips, letting the vice grips lay against the flywheel.

4 - Insert the cord as needed and make sure it is retained properly at that slot.

5 - Feed the cord out the starter cord hole at the front of the engine and attach the handle.

6 - Grip the cord tightly so that the spindle cannot spin around rapidly, then release the vice grips.

7 - Allow the cord to be withdrawn slowly around the spindle.

Thousands of parts in my remaining stock. Not able to list them all. Let me know what you need and I'll look it up for you. Visit my eBay auction at:

joe_omc32 | eBay
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(Manual Starter Cord/Spring Installation)
(This pertains to the side mount type manual starters such as the 4hp models)
(J. Reeves)

Have the rope/cord wound around the starter pulley in the proper direction and tuck the end of the cord under itself to lock it in place.

***emble the manual starter to the engine, having the inner sping loop inserted over the related pin, BUT leave the starter spring UNWOUND and simply hanging thru the slot of the manual starter housing with the long length of the spring out side of the manual starter.

Now, using your ingenuity, rig some kind of device to force that plastic gear up into the flywheel teeth, jamming it so that it will stay engaged in those teeth.

It is now simply a matter of putting a wrench on the flywheel nut and turning it in the proper direction to pull that spring into the manual starter housing which will properly rewind it. After the spring has been pulled in completely, continue to crank it further until sufficent pressure is upon the spring. Usually three turns of the flywheel is enough.

Now, keep a firm grip on that small plastic gear so that the starter does not rewind. Using a sharp pointed scribe, pick the loose end of the starter cord free and run it out its proper exit, then attach the handle to it. That should do it.

Thousands of parts in my remaining stock. Not able to list them all. Let me know what you need and I'll look it up for you. Visit my eBay auction at:

joe_omc32 | eBay
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[jrj2211]

Thanks for your help, I was able to bend some of the coil over and get it all back together.