How to replace the recoil starter on a generator

Few things are more aggravating than a generator that just won’t fire up, especially when you really need it. If you’ve been pulling the cord till your arm’s sore with no success, it might be time to swap out the recoil starter. But here’s the upside: you can handle this fix yourself with some basic tools and a bit of know-how. Let’s go through the steps to get your generator humming again.

Important Notice: What we’re sharing here might not exactly match your appliance model. We do our best to give useful advice for all sorts of DIY repairs, but different models and setups can mean troubleshooting steps, error codes, parts, and so on can vary. For the most precise info, we suggest checking your specific model’s manufacturer documentation or give us a shout with any questions.

Gather your tools and materials

Before you get started, make sure you’ve got all the tools and parts you need:

• Socket wrench set (commonly 8 mm sockets)
• Screwdrivers
• Replacement recoil starter
• Replacement rope and recoil spring (if restringing)
• Liquid wrench or lubricant
• Protective gloves

Can’t find the right parts? Check out our guide on how to locate your appliance’s model number to make sure you snag the correct bits for your generator.

Follow safety precautions

Safety first! Before you get hands-on, please follow these key safety tips:

• Make sure the generator’s engine is totally cooled off to avoid any burns.
• Turn off the engine switch and fuel valve so it doesn’t accidentally fire up.
• Unplug the spark plug boot to knock out any chance of ignition.
• If there’s a battery on your generator, disconnect it to dodge any electrical hazards.
• Throw on some protective gloves to keep your hands safe while working.

Replace the recoil starter: step-by-step guide

Step 1: Prepare the generator

First things first, set your generator on a flat, sturdy spot. Make sure you’ve got enough room to work without tripping over stuff. Keep your tools close by so you don’t have to keep fetching things.

Step 2: Remove the recoil starter

Here’s how you get to and take off the busted recoil starter:

1. Grab your socket wrench and undo the bolts holding the recoil starter housing. They’re usually 8 mm bolts, but this can differ based on your model.
2. If you’ve got an inverter generator or a model with extra covers, you may need to take off some other bits to get to the recoil starter. Remember where each screw and piece goes as you’re removing them.
3. Carefully lift the recoil starter off the generator. Watch out not to mess up any nearby parts.

Step 3: Inspect the new recoil starter

Before you slap on the new recoil starter, it’s important to make sure it’s working right:

1. Grip the new recoil starter and gently pull the cord.
2. See if the pawls pop out when you pull the rope. These little guys connect with the starter cup to crank the engine.
3. If you’re thinking of restringing the starter or reusing parts, take a look at the rope and recoil spring for any wear or damage. Swap them out if needed.

Step 4: Install the new recoil starter

Alright, let’s get the new recoil starter mounted onto your generator:

1. Line up the new recoil starter with the mounting holes on the generator housing.
2. Put the bolts through the recoil starter and into the housing.
3. Screw in each bolt by hand first to make sure they’re threading properly before you tighten them up with the socket wrench. This way, you avoid cross-threading.
4. Tighten the bolts evenly so the recoil starter sits snug against the housing.

Step 5: Reassemble and test the generator

Now that the new recoil starter’s on, let’s put everything back together:

1. Reattach any covers or parts you took off before. Make sure all screws and bolts are tightened up.
2. Hook the spark plug boot back up, and reconnect the battery if your generator has one.
3. Give your work area a once-over to make sure you didn’t leave any tools or parts lying around.
4. Move the generator outside to a spot with good ventilation for testing.
5. Turn on the fuel valve and flip the engine switch.
6. Give the recoil starter a pull to fire up the generator. It should engage smoothly and get the engine going without a hitch.

Apply additional tips and troubleshoot

Restring the recoil starter

If you’d rather restring the recoil starter instead of swapping out the whole thing, here are some handy tips:

• Counting Turns: When you’re winding up the recoil spring on the spool, check your manufacturer’s guide for how many turns you need to get the right tension on the starter rope.
• Securing the Rope: Keep a grip on the rope in the spool before you slowly let it wind back in. This stops the spring from suddenly snapping back.
• Melt the Rope Ends: Lightly melt the ends of the new rope with a lighter. This prevents fraying and makes it easier to thread.
• Lubricate Moving Parts: Put a dab of liquid wrench or some lubricant on the recoil mechanism to keep things moving smoothly.

Troubleshoot common issues

If the recoil starter isn’t acting right after you’ve installed it:

• Check the Alignment: Make sure the recoil starter lines up properly with the starter cup. If it’s off, the pawls might not engage.
• Inspect the Pawls: See if the pawls are popping out when you pull the rope. If they’re stuck, they might need a clean or some lubrication.
• Examine the Recoil Spring: If the recoil spring is weak or busted, the rope won’t retract right. You might need to replace it.

If you need more detailed troubleshooting, swing by our repair help section for in-depth guides and support.

Wrap up

Swapping out the recoil starter on your generator is a doable DIY job that can save you time and cash. With your generator up and running again, you’re set for any power needs that pop up. Don’t forget, regular maintenance can help your gear last longer and keep it running smoothly.

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