How to Replace a Yamaha Outboard Starter Rope Spring

When you pull the starting rope of an outboard, you expect the engine to start. When you pull the rope, and the rope doesn't wind back into the starter, the spring will need to be replaced in the outboard motor's recoil starter. When the rope is pulled out of the recoil starter, the spring is under tremendous tension and quite dangerous if it comes unraveled. A pre-wound spring is available, however, which eases the re-installation process.

Things You'll Need

  • 1/2-inch socket
  • Circlip pliers
  • Plastic mallet
  • Waterproof marine grease
  • Leather glove
  • 5/16-inch box-end wrench
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Instructions

  1. Removing the Old Spring

    • 1

      Remove the three bolts holding the rope starter to the powerhead, using a 1/2-inch socket. Lift the starter from the engine.

    • 2

      Turn the starter so the sheave is face up. Remove the handle from the rope and allow the sheave to slowly rewind the rope. Remove the circlip from the groove, using circlip pliers, and lift the spacer from the center shaft.

    • 3

      Lift the friction plate enough to snap the friction spring out of the hole in the shaft. Remove the spring cover and the friction spring. Take the ratchet out of the top of the sheave.

    • 4

      Rock the sheave while lifting it about 1/2 inch. Turn the housing over and place it on the floor so the spring faces the floor. Step on the housing and tap the housing with a plastic mallet. Tilt the housing away from you. Turn the housing over and unhook the spring.

    Installing the New Spring

    • 5

      Apply waterproof grease to the new spring. Hold the spring in a leather-gloved hand and, with the other hand, install the hooked end of the pre-wound spring to the housing spring.

    • 6

      Lower the sheave over the shaft of the housing so the hook on the bottom face of the sheave fits into the loop at the inner end of the spring. Add the ratchet to the sheave so that the flat side of the ratchet is against the sheave. Slide the friction spring down the shaft.

    • 7

      Position the ratchet in place on the sheave, with ratchet's flat side to the sheave. Place the friction plate over the sheave. Place the spacer over the hole in the friction plate. Push the plate down and reinstall the circlip.

    • 8

      Replace the rope into the notch in the sheave. Rotate the sheave three turns counterclockwise while holding tension on the rope. Feed the rope through the rope guide in the starter housing. Replace the handle on the rope.

    • 9

      Pull the rope to the handle recess. Allow the sheave to rewind. Bolt the starter back onto the engine.