Intermittent Pull Start Issue (pinion not engaging on starter pulley)

[JohnnyGuy]

I have a 76 15hp Johnson.

As purchased the pull cord is not tight to the lower cowl, it hangs loose approximately 3-4 inches.

We were experiencing intermittent issue with the pinion gear not engaging (or running up the splines of) the starter pulley to engage the flywheel.
When this happened we had noticed that the pinion spring was falling into the groove of the vertical arm of the cup spring. A quick flip of it out of the groove and the gear would then follow the pulley splines and engage the flywheel.

I was wondering if I were to just pull out the starter rope until there was tension and affix the handle at this location if it would likely solve the issue?

Perhaps someone else here has experienced this before though and can provide further comment/direction?

Thanks in advance,
JG

 

[tomhath]

Does it look like the rope was replaced? If so it might just be too long or too thick of a rope. I'd check the spring to be sure it isn't gummed up with old oil first though.

 

[JohnnyGuy]

Does it look like the rope was replaced? If so it might just be too long or too thick of a rope. I'd check the spring to be sure it isn't gummed up with old oil first though.

I believe the rope is too long.
Nonidea if its been replaced. The pull handle itself is not the original.
The rope does recoil fine, theres just always 3-4in of rope hanging out.

 

[oldboat1]

Hold the rope out just past the tension point, using a pair of vise grips. Attach the handle at that point, but don't cut the excess rope until you're sure it's going to do the job.

 

[interalian]

I just had an '81 9.9 with the same problem. I just cut the knot after pushing it through the handle, ran the cord back through into the motor housing and put two turns more around the pulley while holding it firm. Then I pulled the rope back through about a foot, secured with vice grips, threaded through the handle and knotted it again. Worked fine. I think somebody had it apart and pulled a couple of turns off the pulley but had no clue about how to fix it.

 

[JohnnyGuy]

Thank you oldboat1 and interalian.
I will try that. Thats what I was hoping might be the answer.

 

[interalian]

Oh, and that horseshoe spring needs to sit in the groove under the starter gear. It adds just enough friction so the gear will climb up to the flywheel. I used some dry-lube on the inside of the starter gear so it would rise more easily. Grease would work against you.

 

[JohnnyGuy]

I took a look at this today. I shortened the starter like mentioned and it seem that the pinion gear engages the flywheel much more consistently. Though it's obvious that I need to pull apart the recoil this winter and clean everything up as the starter rope is slow to recoil for the last 3-4".

 

[interalian]

I'd try spraying some WD-40 into the recoil spring rather than take it apart, then work it a bunch of times. Most likely there's gummed up lube in there and the WD-40 will re-activate it.