Problem with recoil starter on '84 Johnson 8 hp

[Valley Boater]

I got out my fairly "new to me" 1984 Johnson 8 hp over the weekend for a tank test before fishing season. Since I got this motor 2 years ago the starter pull rope was usually limp by an inch of so when not running. I tried to start the motor yesterday and found that the rope didn't retract into the motor until I reduced the twist grip throttle from "start" to "slow" or "stop" and even then it rewound very sluggishly. It looks like the previous owner had reduced the length of the pull rope as the spool looks to be only half full. I believe the spool should have 56 1/4" of rope and I have about 36" when the rope if fully extended. There was a lot of grease on the rewind assembly which might have been the previous owner's attempt to get the rewind smoother.

My thought is I need to replace the rope with the proper length and at the same repair time carefully release all the tension on the spool spring and re-tension at 16 1/2 turns (CCW - thanks Lee Roy) before re-spooling. Does this sound like the best first option? I'm confused why the throttle would bind the rewind process.

Thanks for all suggestions.

Don

 

[Vic.S]

Re: Problem with recoil starter on '84 Johnson 8 hp

Hi I have the 6Hp version. Identical in practically all respect to your 8hp

I have never had to renew the starter cord but have looked at it closely to see what would be involved

I have a note that says that the cord is 59?" long and is 3mm diameter.

I also have a note to say that the spring is pre-tensioned by 12? turns although I have altered that from 16? turns. Not sure therefore which is correct. ( I'd try 12? initially I think rather than wind it up too tight)

The spool is full all but the bottom turn of the groove. The photo below shows that ( the bottom turn is black/dirty!)

There should be no more than a light smear of grease.

If the throttle is opened beyond the "cranking" position the interlock will prevent the spool turning.
Even then when you turn it the pinion will try to rise and engage with the flywheel ring gear but you can prevent this happening by turning the spool with the pinion

 

[Valley Boater]

Re: Problem with recoil starter on '84 Johnson 8 hp

Yesterday I pulled out the old starter cord fully and locked the spool into the pinon with pliers from below. I removed old rope and removed the pliers while holding the assembly and gently released the tension on the spring as I didn't think it was tensioned correctly . I then carefully wound the spool 12+ turns (counter clockwise) and it seemed to come to an abrupt stop so I didn't force additional turns. I locked the assembly with the pliers and installed the new 3 mm rope on the spool. I removed the pliers and carefully let the spool rewind. It didn't wind all 56 1/2" of the rope initially (lacking about 2") but the motor started fine and when running pulled in the little slack. I may have a weak main spring but I can live with it. Perhaps this will help someone else with a similar problem.