pull cord...

[woodstockii]

I went to Home Depot the other day and got 5/32 "metal rope" as they call steel cable (preferablly the cable with the plastic around it). And installed it into the 200s recoil. So far it works. It's only had maybe 20 pulls on it so far.. Geez the Idea of never replacing a rope. I sure hope the recoil can with stand strength of "metal rope". all cable and hardware was a buck or two...

[250RWANTER]

Alright, I got it off and thought I did as you said, but he plastic 'pulley' came out. And he spring that attaches to that came out. I thougt I put it all back together right, but I guess not. It worked great before I put the final washer and E clip on. THe I pull and it recoils REAL slow and doent take the rope all the way in.
I dont know what I did and I took it back apart an did it agian, same thing.
I wound the metal pulley up abou 6 time like suggested, held it there, used piece of wire to pull the rope through, tied it in a not and let the recoil pull the rope back through. Everything worked fine until that retaining E clip and washer were put on.

Any ideas on what I did wrong? The plastic outter ring doesnt have to be in a certain spot in relation to the center metal pulley (that the rope works around) does it?

Does it matter if you put the outter plastic ring on with the rope all inside? Or does it have to be unwound or?

This is frustrating taking it apart 3 time and evertime is wrong! :Evil

[hondatrikesrule22]

You need to wind it more. 6 times doesn't put enough tension on the spring and doesn't suck the rope back in. Keep trying...

[250RWANTER]

Wow, that is gonna get difficult isnt it!
So its normal for it to work good, suck it back in no problem before the final clip if its not wound enough? Cuase it work great/fast before that final center spring, washer and E clip is o.

Just wanna make sure its not something else.

Sounds like you may have had this problem before though

Now do I HAVE to pull out the outer plastic ring? I think I do, but I wanna make sure I am not doing 'extra' steps

Once I get the rope in, I can let it suck itself in and then reasseble the outter plastic ring etc, right? It doesnt have to be assembled with the rope out/tension on everything?


Thanks alot!

[250RWANTER]

seeing how much of a PIA this is, I am wondering if I should just go get some metal cale and clamps an be done with it! But I see some dont use the plastic coating because it comes off. What keeps the non coated cable from rusting?

Also, what keeps water from getting in the the hole in the cover where the rope comes out?

[hondatrikesrule22]

Yes, I have had this problem before. I have found cussing alot helps. LOL. Uh, yeah it sounds like you got it. Just refrain from pulling the rope before the clip and all thats on, because it will make that big spring come out(had that happen before). Yes, you can let rope suck itself back in then assemble the rest. thanx PS, you should go ahead and put the metal cable in while you have it apart. Nothing keeps the cable from rusting, but I think with the coating it would hold moisture in and speed up the process. I would think the handle keeps the water out pretty much.

[250RWANTER]

sweet! Thanks! Guess I'll go pick up some metal cable and the clamps.
Is there a special tool for to crimp the ends I need to get or?
5/32" I guess is what I'll get....I think thats what I saw....actually the 1/4" rope was a little difficult to get through....maybe I'll get 1/4" cable...or even 3/16".
I am sure even 3/16' cable has to be stronger than rope!

[hondatrikesrule22]

Well, the 5/32 might work with yours. Because I replaced a rope on a 110 and they have huge openings for the ropes. I am sure the pull starter cases can't be too much different. Oh, I just read your post again, you should get the 3/16". I am pretty sure the cable is much stronger than rope lol. I am going to get some cable tommorow. I hate replacing ropes. The problem I have is not how strong the rope is, just that it gets worn away by being pulled so much(with the peices of crap I buy lol). thanx PS you shouldn't need any special tools, actually, with the clamps they were talking about, I think it is just a couple bolts you tighten on the clamp.

[250RWANTER]

I was thinking about the cable.....do you think that would wear away the aluminum/metal constantly rubbing against it where it comes out of the case? Hmmmmm....then metal shavings wouild get inside....wonder if its really worth it.
what do you think?

[woodstockii]

there should be calmps on the shelf right near the cable. I got the type that just crimp on..I have also wondered about wear on the recoil itself, but oh well..

[hondatrikesrule22]

I would rather replace housings than those damn pull-ropes!

[UtahLugers]

Pull Start Rebuild - This Is All That You Will Need

[250RWANTER]

I already did two of them, a little different than you showed, but it worked. That is a great write up!

as far as the 'Geeze' comment, not sure how you meant that, but if someone hasnt done it before, they are not gonna know, and you dont learn unless you ask questions.

That link should be made a sticky or put in a tech write up folder on the site.
I am sure i am not the last person who will be asking this same question
Thanks guys!

[canadiandevil2]

wow thats way different than the one on my '84 200 M. I ripped the cord right out of its housing all i did was wind up the pulley tie my cord back in and let it go. it winds up the cord then I put it back on my bike.