How to Rewind Outboard Alternator Coils

Small and older model outboard motors are started with a manually operated pull chord. When the cord is pulled, a fly rod is spins and the inertia sparks the plug and fires the engine. After the cord is released, an alternator coil -- or spring -- rewinds the cord into the alternator housing. In order to replace the cord, the housing must be disassembled. Included in the disassembly is the removal of the alternator coil. After the new cord is seated in place, the coil must be rewound.

Things You'll Need

  • Flat-head screwdriver
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Instructions

    • 1

      Lay the coil flat on a work bench. Looking from above, one end of the spring should be at the perimeter of the natural circular shape of the coil, the other end is in the center at the radius of the circle. Follow the wind of the coil with your eyes or a finger and make certain no part of the coil overlaps another. If there is overlap, pull on the circumference end of the coil with one hand while holding the radial end with the other, then slowly bring your hands together allowing the coil to rewind.

    • 2

      Slide the eyelet of the circumference end of the coil over the housing pin located on the edge of the alternator housing. Place a flat-head screwdriver in the eyelet of the radial end of the coil and twist it by turning the screwdriver. The twisting motions must reduce the size of the circumference of the circle. If the circumference increases, twist in the other direction.

    • 3

      Twist the coil until each band of the spring is compressed against the other. Maneuvering the coil with the screwdriver, place the head of the screwdriver on the radial pin of the alternator housing. Push the coil off head of the screwdriver and onto the radial pin. The radial pin maintains the tension on the spring. Put the cover on the housing and secure it in place.