Any trick to threading starter rope thru handle?

[jspringator]

Is there any trick to threading starter rope through handle on an Evinrude 25? The shop manual says to use a special tool, but I'm sure that is no longer available.

 

[Joe Reeves]

Re: Any trick to threading starter rope thru handle?

Special tools are still available, However........

Use a piece of single strand steel wire, long enough to be threaded thru the handle. Have the other end of it pushed thru the nylon cord and folded back over like a hook. Now, simply pull the cord thru the handle.

Hint..... The end of the cord, heat it with a torch, lighter, or match so that it melts somewhat and slide a piece of fabric (or something) over it to form a point of sorts. Spray a slight bit of WD40 into the handle slot to act as a lubricant.

 

[wbeaton]

Re: Any trick to threading starter rope thru handle?

Special tools are still available, However........

Use a piece of single strand steel wire, long enough to be threaded thru the handle. Have the other end of it pushed thru the nylon cord and folded back over like a hook. Now, simply pull the cord thru the handle.

Hint..... The end of the cord, heat it with a torch, lighter, or match so that it melts somewhat and slide a piece of fabric (or something) over it to form a point of sorts. Spray a slight bit of WD40 into the handle slot to act as a lubricant.

I cut mine on an angle, heat it and roll the end on the work bench. This keeps the end from fraying, slightly tapers it and makes it easy to push through. A little spray oil helps too.

 

[jspringator]

Re: Any trick to threading starter rope thru handle?

Could I fuse the wire in the melted nylon? The directions say I'm supposed to lose 1/2 inch in fusing each of the ends, and the knot on the starter is supposed to have a 1/2' tail. I'm only replacing the rope because the timing mark doesn't line up. I may experiment with shortening the rope on the starter side until it lines up. Will I be able to extend the rope all the way, put in the nail thing, and pull the rope backwards to be able to do this?

 

[Joe Reeves]

Re: Any trick to threading starter rope thru handle?

(Manual Starter Cord Installation -Over The Flywheel Type Only)
(J. Reeves)

For what it's worth, my method of installing a new cord on the over the flywheel type manual starters is as follows.

Arms outstreched (approx 6'), I cut a proper size nylon cord that length, tie a figure 8 knot in one end, then melt the ends with a flame to prevent unravelling, using a rag to form a somewhat point on one end. No cord in manual atrter pulley.... wind pulley to it fullest point. Keeping a good grip on the pulley, let it slide back to where the cord hole in the pulley aligns with the manual starter housing cord hole, then install the cord.

Now, keeping a good grip on the cord, slowly let the manual starter rewind pulling the cord in. In most cases, the cord will be too long so install the pull handle accordingly so that the handle retracts completely.

This is the way I've performed this procedure for quite a number of years and regardless of the design of the pulley, I encountered no problerms.

 

[jspringator]

Re: Any trick to threading starter rope thru handle?

Got it through. Cut the end at an angle so it fused in a point. Tried the ink pin "fid" method in another thread, but the end of the pen broke off inside the handle! Got it out (finally). Lubed the handle good (WD40) and started pushing the rope through by hand. When it stopped, I pushed it through with a rope braiding tool (long thin metal rod with blunt end and with handle on the other end) that I found in the hardware drawer. It made it through and I grabbed the end with a pair of needlenose pliers. It timed OK, but still had a little room for rope seating, streching. Rope length is critical.

People who do this should go on and get a new handle. Mine had a piece missing. I'm storing the old rope (which was much shorter) in the tool box to use as an emergency starter rope.

 

[Joe Reeves]

Re: Any trick to threading starter rope thru handle?

It's odd that you went to all that trouble when a time proven method was thoroughly explained. Makes one wonder why we bother.