Monday, March 7, 2011

Fixing Old Outboard

I have been working on my 1989 4 horse Yacht Twin.  I had to replace the starter rope.  I found two sites on the web that listed parts and even showed an exploded parts diagram.

http://shop2.evinrude.com/Index.aspx?s1=pe5e4rk9mctkcjjsth2it1es24&catalog_id=0&siteid=1


http://epc.brp.com/SiteMods/BRP_Public/BRP_Public_Login.aspx?ReturnUrl=%2fIndex.aspx%3flang%3dE%26s1%3d9cf114bc-5aed-4595-834b-00256b3e1020%26brands%3dej%26dealerlocator%3dno&lang=E&s1=9cf114bc-5aed-4595-834b-00256b3e1020&brands=ej&dealerlocator=no

Long links, but you can cut and paste to your browser.

The key part for me was the diameter of the starter rope.  It is listed as 1/8 inch.  The rope is available from one part site in 200 foot roles and from another by the foot with a $7.50 service charge.  I went to a STIHL chainsaw dealer and found a pull rope that is the right size and got my 52 inches for $1.25.  The line was a roll that they stock for a weed whacker, not a chainsaw.  The chainsaw line is too thick.  Beware of just plain old 1/8 inch diameter line sold in the big box stores.  It doesn't have a core and will stretch, both bad things for outboard pull ropes.

I found a number of forums that gave advice about how to put in a new starter rope.  One of them told how to wind the spring assembly, use the hole in the lower section to put a screwdriver in to hold the spring wound and then thread the pull rope into the connector.  Then you release the spring, keeping tension on the rope, and it will wind the rope onto the drum.  I tried it and it worked like a charm, the third time.  Don't ask about the first two tries.

Be very careful with the spring.  It can and will shoot off into your workshop.  It can bite you.  I found a set of vise grip pliers very useful in hold the whole shebang together while I was working on it.