200s Recoil problem

[ChrisG]

I have the recoil all back together but I am having problems with the plasic cover and the friction spring.

I took photos of exactly what I got so I can get some help.
The friction spring is on the seat.

[ChrisG]

bump - Any idas???

[ChrisG]

Still need help - anyone?

[Howdy]

Patients please! Not everyone lives on the forums, most of us have other things going on also. You will find that normally the most knowledgeable users are the ones that are busy working on something or out riding something they have fixed already. They are doing this instead of living on the forums, just waiting to reply to a new posting.

There is no need to bumb a post 2 times in 1 day. Please do not do this in the future. Do I know your answer? Yes and No. I can and have fixed the decompression style pull starters. They are a royal pain to put together ( IMO ). It is pretty hard to spell out how to put these together correctly. I know I can fix them, but I can't explain it with out one in front of me.
My best advice is to use a manual, if you don't have one you will find it is a very good investment to get one. They can be bought for $10 on up. If you use the manual 2-3 times it will have paid for itself.
Thanks
Howdy

[Kryten]

I've rebuilt that same 200, 200S recoil starter more than a few times and it is kind of tricky even with a manual.

First remove the metal plate from the hook case(yellowish thing) by removing the four small screws. Also it is easier to remove the decompression cable from the bike since you need to insert the one end into the recoil housing when putting it back together.

Here are the general steps from the manual. Hope this helps.

1. You need to partially install the spring onto the raised portion on the drive pulley. Leave 90 percent of the spring completely out of the raised channel.

2. Positon the protruding ends of the spring in the corner opposite where the rope exits the housing.

3. Insert the decompression cable into the housing. The outer cable sheath must not come past the rubber grommet and into the surface of the housing.

4. Install the end of the decompression cable onto the hook plate(small curved metal piece thas has an opening down the center). I didn't see the hook plate in your pics but you definately need this. The hook plate rides on a specific spot on the hook case(yellowish thing).

5. Hook the end of the spring onto the hook case and install the hook case into the housing.

6. Make sure the spring is on the drive pulley and not binding on the hook case.

The manual doesn't get specific with the exact placement of the spring, hook plate, and hook case although they all must be in the right location or everything just won't work right. It took me lots and lots of trial and error to get it right.

Good Luck!

Have any questions let me know, I'll do my best to describe everything.

[Huffa]

Here is the whole deal in pictures. This should help you for sure.

http://www.3wheeler.org/vb/showthread.php?s=&threadid=14675