Re: pull start spring replacement
Here's what the OMC manual for a 1974 6hp says. Anything in () was added by me for clarification.
I know it will be hard to decipher without the diagrams or a parts manual but I hoping it will help a bit.
REASSEMBLY OF STARTER
a. If removed, heat spool bushings in hot water and install on spool.
b. Place starter head with pinion gear spring on starter spool.
c. Insert spring retainer in spool. Place pinion gear on spool. Align slot in gear with holes in spool and spring retainer. Insert roll pin with its split seam in horizontal position to avoid dragging against slot in pinion gear. See Figure 7-5. (which I wish I could provide but don't have a scanner to turn a pic of it into a jpeg).
NOTE: Do not lubricate pinion gear. Oil here will attract dirt, causing pinion to bind on spool. Lubricate upper and lower spool busings with a drop of outboard lubricant. Apply OMC Sea-Lube* Anti-corrosion Lube to spring on pinion gear. See Lubrication Chart, pages 2-4 and 2-5. (The chart basically says to re-lube the anti-corrosion Lube every 60 days for freshwater use and every 30 days for saltwater use)
d. Insert spring into bottom of spool; turn to engage with slot of spring retainer.
REASSEMBLY OF STARTER TO POWER HEAD
a. Place bushing in spring retainer plate.
b. Twist spring to lock inner spring retainer. Pull end of outer spring out of spool and lock spring on retainer. See fig. 7-9.
c. Place guide into starter plate. Insert spring hook into retainer plate slot. Raise retainer plate to hold spring. Install front retainer plate screw and tighten rear screw. Remove spring from spring retainer. Install starter assembly to intake manifold.
d. Raise pinion gear to engage flywheel and lock in position with handle of pliers. (No diagram so I will have to describe - use handle portions of pliers under the pinion gear, with the head, or jaw section, of the pliers facing the rear of the motor, rest the jaw section on top of the throttle arm where it makes the transition from vertical to horisontal) Turn flywheel clock-wise with wrench (on crankshaft nut) counting 16-1/2 turns of pinion gear.
e. Install rope as described in Replacement of Starter Rope.
REPLACEMENT OF STARTER ROPE
(a. through c.: Have to do with removing the old rope, which you have already done.)
d. Cut new rope to a length of 56-1/2 inches, and fuse ends over a flame for a length of 1/2 inch. Ends must be stiff to hold in in spool or rope anchor. Thread rope through slot into starter spool.
e. Thread rope through motor cover and install rope handle using Threading Tool part number 378774. See Figure 7-5. (This just shows a tool to get the rope through the rubber rope handle. It really isn't that hard to get it through without one).
f. Holding starter rope handle to keep starter from rapidly rewinding, remove pliers from under starter pinion gear ( see item "d" in Reassembly section, above) Allow starter rope to rewind normally.
