Hello, I just purchased a 82' honda 200 trike. It is running great but my pull cord just broke. I have taken off the housing but I can not figure out how to replace the cord. Did I mention that I am not mechanically inclined at all . Any help would be greatly appreciated. B

 

happend to my lt125 suzuki quad runner, i just said screw it and push started it lol. sry i cant help gl.

 

Very easy to fix, but also very easily made into a nightmare if you're not careful and the spring below the pulley let's go....LOL


[1]Take the entire recoil housing off from the engine and lie it down with the Honda logo faing downward. [Keep it in this position through the entire process!!!]

[2]Remove the snapring and washer in the center [Be careful that you do not loose anything when you do this. There is a tension spring under there]

[3]Now, remove the friction plate, 3 dog springs, 3 dogs, friction spring, and friction washer.

[4]SLOWLY remove the pulley from the housing by pulling straight up. There is a spring winding underneath that is absolute hell usually to get back right if it's disturbed, so be careful doing this. With the pulley now removed, simply remove the old remaining rope.

[5]Go ahead and put your new rope [6']through the hole in the pulley and tie a knot in it at the end like the old rope. Only wrap the rope around the pulley one complete revolution and be sure you have it going the right direction so that it will make a straight shot through the hole on the recoil housing.

[6]Take the other end of the rope and put it through the hole on the recoil housing and go ahead and put your handle back on. Don't worry about the excess rope lying around right now. Winding the rope will be the last thing you do.

[7]Carefully slide the pulley back onto the shaft taking care to align the tab underneath with the tab on the spring winding in the bottom of the housing. Also be sure that the rope is aligned with the notch in the pulley so that your rope doesn't hang up putting the pulley in place.

[8]Now, reinstall the friction washer, friction spring, 3 dogs, 3 dog springs, and friction plate. After they are in place, press down on them and put back on the washer and snapring that keeps them all in place.

[9]Take the rope by your hand right where it is align with the notch and start winding. This is winding the spring so that it will pull the rope bak in. Usually, it will take 4 to 5 rounds to get the tension right. After you have wound it up, hold the pulley from turning with your hand and take your other hand and pull the handle until all the rope is outside of the housing. Once, you do this slowly release tension on the pulley with your hand until the rope goes bak into the recoil.

[10]If for some reason, you still have rope that wont go in, repeat step 9 until it does. Keep in mind that the spring will only do so much. If it takes more than 8 windings, the spring will break. If you get to this point, your rope was cut too long and you will need to shorten it up a bit.

Have fun!!