'68 Johnson 3hp pull chord/spring replacement

[Chattahoochee]

Hello - I'm sure this is typical of a new boat owner. I broke the pull chord and am trying to fix it my self. I got the starter pulley and spring cup assembly off, inserted the new chord and knot, and put the starter assemble back on without too much trouble and the spring exploding and taking my head off. But now I can't seem to rewind the spring. Any suggestions on how to do this? I'd rather not spend $50 on a repair manual right now.

 

[Joe Reeves]

Re: '68 Johnson 3hp pull chord/spring replacement

(Manual Starter Assembly)
(This pertains to the type of Manual Starter Housing that sits over top of the flywheel)
(J. Reeves)

Lay the manual starter housing upside down on the workbench.

Wind the spring "counter clockwise" in your hands so that you can lay it into the housing, having the outer spring end hooked over the retaining pin. Make sure the spring is in there properly (You do not want it to fly out of there).

Holding the spring down, with pliers carefully bend about 3" or 4" (more or less) on the inner portion of the spring in towards the center of the housing. This will allow the pulley pin to enter the retaining hole at the end of the spring properly.

Lay the pulley down over the spring, making sure that the pin on the pulley is secured to the retaining hole on the end of the spring. Install the spindle (center bearing gizzmo), bolt, nut, etc, whatever your particular manual starter may use.

The cord (nylon) should be roughly 72" long. Have a figure 8 knot in one end. Heat the other end so that you could form a point on it, wiping it with a rag when it's burning or hot to a melting point.

Now, with the starter housing still upside down, keeping a firm grip on that starter housing and also the pulley, start winding the pulley in the normal counter clockwise direction. Wind it as far as it will go, then carefully let it back off until the starter pulley cord hole is aligned with the housing cord outlet.

Hold the pulley there and insert the cord in through the inside of the pulley and out through the starter housing. Pull the cord through completely and get a good grip on it. Now let the pulley retract the cord, but hold onto the cord (don't let it fly in there).

If it's obvious that the cord is too long, figuring what will be needed within the handle, shorten it as needed.

Pull the cord out so that about two feet of the cord is exposed. Tie a slip knot so that the cord can't retract back.

Insert the cord into the handle and secure as needed, then release the slip knot allowing the cord to be withdrawn fully. That's all there is to it..

 

[Chattahoochee]

Re: '68 Johnson 3hp pull chord/spring replacement

Reeves - Thank you very much for the information. The starter assembly on my motor is on the side though. It's obvious I need a repair manual but if could have some advise for the side mounted assembly that would be great. Thanks.

 

[tx1961whaler]

Re: '68 Johnson 3hp pull chord/spring replacement

Here is the page from a pretty crappy manual for the 1968 model

 

[Chattahoochee]

Re: '68 Johnson 3hp pull chord/spring replacement

tx1961whaler - Thanks for the page. That's good information. Is the manual worth buying if it's crappy? This page seemed helpful. It wasn't complete though and I'd like the rest. Is the manual worth buying for the rest?

 

[Joe Reeves]

Re: '68 Johnson 3hp pull chord/spring replacement

(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.

Assemble 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.