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Old 27 January 2014, 08:54   #1
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2004 Tohatsu 18hp

I need to replace the pull-cord on my engine - but am kinda nervous with what lurks underneath the housing
I removed the housing yesterday and gently looked between the plastic disc(which holds the cord) and the housing....where the spring lives Quickly put them back together again

Now, I need to know how to replace the cord; should the shite hit the fan when out on the boat.......so any pointers for a first timer??
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Old 27 January 2014, 09:03   #2
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Down load the owners manual from

Www.tohatsu-uk.net

You should find out what is required from there

Steve

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Old 27 January 2014, 09:05   #3
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Its easy enough, just make sure you have the new one ready to go on as soon as you take the old one off so the reacoil doent recoil itself.

You might get a better idea from the parts drawing here:
Parts for Tohatsu M9.9D2 M15D2 & M18E2
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Old 28 January 2014, 01:53   #4
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Quote:
Originally Posted by Ribshop View Post
Its easy enough, just make sure you have the new one ready to go on as soon as you take the old one off so the reacoil doent recoil itself.

You might get a better idea from the parts drawing here:
Parts for Tohatsu M9.9D2 M15D2 & M18E2
Thanks, but I have the owners and parts books........it was more 'hands-on' information I was looking for - the spring is held at one end with the pin fixed into the top housing, the other end of the spring looks like it's against a stopper on the plastic pull-cord winder disc.......so when you try to seperate them; the spring wants to pop

Anyone else replaced the pull-cord?
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Old 28 January 2014, 08:58   #5
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Flip recoil starter, pull complete cord untill you see an empty spool, grab spool with extra mate help. Secure new cord end to starter handle, untie old cord from where it locks, place a new cord, tie new cord knot exactly as previous one. Gently release reel back and check cord winds evenly on reel and voila.

If you release reel back, won't know number of turns the spring was factory delivered, that's why need to hold it when changing cord and assuming you don't have already a broken cord which is a different assembly procedure.

Happy Boating
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Old 28 January 2014, 13:06   #6
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Flip recoil starter, pull complete cord untill you see an empty spool, grab spool with extra mate help. Secure new cord end to starter handle, untie old cord from where it locks, place a new cord, tie new cord knot exactly as previous one. Gently release reel back and check cord winds evenly on reel and voila.

If you release reel back, won't know number of turns the spring was factory delivered, that's why need to hold it when changing cord and assuming you don't have already a broken cord which is a different assembly procedure.

Happy Boating
Yeh, thought of that way Loco, thanks.....was thinking more of when there is complete failure and the spring has sprung so to speak
I have considered removing the housing and wrapping the spare cord around the flywheel and giving it a tug - which would get me out of a situation no doubts - but would still need to rewind the spring and set new cord when back on the dry land
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Old 31 January 2014, 14:18   #7
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When recoil starter is inioperartive due mostly when having a broken spring, you must remove complete upper assembly and start engine by means of a rope wrapped some turns on fkywheel. It's good to carry the wrench socket size needed to remove 3 bolts at an emergency, including a proper lenght rope for that matter.

Happy Boating
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