1993 Johnson Evinrude "ET" 9.9 thru 30 Service Manual, P/N 508282, Page 272Get this manual
Cleaning and Inspection 1Wash metal components in solvent and dry with compressed air2Inspect the rewind spring for broken end loops and weak tension3Examine the pawl for wear, and inspect the links4Inspect starter ropeReplace if frayedCut new rope to 59112 in(151 em) lengthFuse ends of rope to length of 112 in(12 mm)5Examine the pulley and the starter housingLook for sharp edges and rough surfaces that could fray the starter ropeFile and polish to remove6Examine starter lockout partsReplace any worn or damaged partsAssembly
i manual starters because of rewind spring tension
Wear safety glasses while disassembling and assembling
1sl1To replace rope, tie knot in one end of rope and feed through channel in pulleyWind rope around pulley counterclockwisef912Apply OMC Triple-Guard grease or Lubriplate 777 to the rewind springPlace inner loop of rewind spring in the pulley baseWind the spring into the starter housing base until end of rewind spring contacts the starter housing basecenter of the starter housingEngage the slot of the pulley with the inner loop ofthe rewind spring while installing the pulley in the starter housing4Clean threads of the spindle retaining screw to remove adhesiveInstall the spindle and retaining screw into the starter housingSpray threads of spindle screw and threads of the spindle with OMC Locquic PrimerApply OMC Nut Lock to the threads of the spindleTorque the spindle screw to 120-145 inIbs(14-16 Nm)r:t1'l5Prewind pulley about 112 to 1112 turnsThread the starter rope through the hole in the pulley and out through the starter housingWith the starter housing upside down on bench, wind the pulley counterclockwise until the rewind spring is tightTie slipknot in the end of the starter ropeBack off the spring about 112 to turn