1969 Evinrude 40 HP Big Twin, Big Twin Electric Lark Service Manual 4596, Page 102Get this manual
dJ the housing, bottom side down, on the bench to dislodge spring and pulley CLEANING, INSPECTION, AND REPAIR
a Wash metal components in solvent such as Solvasol and dry with compressed airbInspect spring for broken end loops and weak tensionc Examine pawls for weardInspect friction ring and spring, spindle bushing, spindle, and retainersFigure 9-5Winding Spring Inspect rope and discard if frayedBe sure to replace with starter rope cut to length of 73-3 inchesfExamine pulley and housing eye for sharp edges and rough surfaces that could fray ropeFile and polish to remove
bPlace the pulley in position on the base plate, making sure that the center pin fits into the center loop of the springInsert bushing and handle into pulley and base plateUse fixture crank to wind spring in counterclockwise directionSee Figure 9-5cWhen the spring is wound tight, release at least one turn, continuing to release until loop in spring lines up with hole drilled through edge of pulleySlide the dowel pin through hole in pulley and spring loopSee Figure 9-6dCarefully remove the hand crank and bushingLift pulley off base plate, holding spring in pulleySee Figure 9-7Lubricate spring with OMC Type itA" lubricantePlace pulley and spring into starter housing, making certain that the outside spring loop is on top of its appropriate stud in the housingPress down