I have a 1997 Trail Boss 250. My starter began giving my problems a couple weeks ago. I would press the button and it would just spin but not engage. I would immediately release the button and when it stopped spinning I would hit the button again. It would now engage and start right up. This weekend when I went to start the motor I got the same spin and no engage. I hit the button again but now it will only click. I pull the recoil to start the motor but it pulls out and stays out. I have used the recoil before without any problems although the spring tension did not seem very strong. I was able to get it running by taking the recoil cover off and pulling the rope after manually winding it around plastic reel.

I assume the recoil spring is broken and I have ordered a replacement. I understand from reading previous posts on this site that I have to take recoil assembly off of the motor and then use a vise to lock the bolt in place while I spin the plastic reel off. While replacing the recoil spring is there any tricks/tips to putting everything back together? I think I read something about being sure to line up the notches or something. I also plan to clean the flywheel and starter while I'm in there, hopefully this will get the electric starter back functioning. If not thats OK because the engine starts on the first or second pull.