D=600 SERIESSTARTER SAFETY WARNING WEAR SAFETY GLASSES WHEN REPAIRING STARTER. REMOVING STARTER ASSEMBLY To disassemble starter, pull starter rope out about two feet and tie a slip knot next to rope guide hole. Untie knot securing starter handle, This may require use of two pair of pliers. If you have to cut rope, fuse end to eliminate fraying. Remove starter handle. Pull slip knot out of rope and allow rope to rewind on pulley. To loosen 7/16 inch screw securing starter assembly to armature plate, carburetor and reed plate assembly must be removed from crankcase. This is necessary because of closeness between this screw and reedplate. NOTE Keep dirt out of open crankcase. Remove starter assembly from armature plate by grasping it between thumb and fingers of both hands. Hold starter assembly firmly together to keep spring loaded pin and cup assembly from separating from starter pulley. Starter spring is loaded and; potentially harmful if released. Set starter assembly on bench, flat side down. 7-4 SERVICE BULLETIN REFERENCES
D-600 SERIESSTARTER With starter assembly on bench, flat side down, remove retainer ring with a screwdriver. Remove pinion gear from worm gear. Never lubricate worm gear clean and dry. keep it Remove three self tapping screws from starter pulley and remove retainer plate. J SAFETY WARNING There is still tension on starter spring. To remove tension, hold two halves together, pointing shaft downward. Now drop assembly on floor (shaft pointing downward). Halves will separate and release spring. Examine starter spring carefully for bent or weakened areas. Spring steel is quite brittle and is damaged easily if bent or twisted. A light coating of grease must be applied before reinstalling. Re-anchor spring in anchoring channel of SERVICE BULLETIN REFERENCES 7-5
Grasp pin and cup assembly and wrap your fingers over worm gear plate to hold two pieces together. This will keep the spring contained so that you can rotate worm gear in a clockwise manner, winding spring. Continue winding until spring is drawn into cover and end hook rests in recess. Carefully let spring unwind slowly until it is relaxed. Be sure beveled sharp edge of retainer plate is away from rope. Re-anchor rope and put rope retainer plate on and rewind rope in clockwise fashion. Replace pinion gear and retainer. Starter assembly is now ready to re-install. Pinion spring must be positioned properly during starter assembly installation, one prong goes above armature plate ledge and the other below. Before tightening screw securing.starter assembly make sure that spring end hook faces up and locates in die casted recess in armature plate. Push starter assembly in as far as possible then back out approximately 1/32'' to provide clearance between starter worm gear and magneto plate casting. 7-6 SERVICE BULLETIN REFERENCES
NOTE On 1975 and 1976 D-600 Series engines, the magneto plate was redesigned. An "Azdel" (type of fiberglass) shroud mounting base was added to reduce engine noises. A dimple in the shroud mounting base located above the hose bracket is used to position the starter assembly. Before tightening the starter assembly clamping screw, pivot the starter assembly clockwise until top of hose bracket is contacting the bottom of this dimple. Top of the hose bracket should be no more than.020 inch below the dimple. On all 1972 thru 1974, and early production 1975 model D-600 Series engines, slide the starter assembly all the way in, then back it out approximately 1/32" before tightening the starter clamp screw. Mark a spot on starter pulley and pull enough rope out so that mark rotates approximately two full turns. Grasp starter pulley and spring housing firmly to keep pulley from returning to its relaxed position and wind excess rope around starter pulley.
STARTER ASSEMBLY 1976 MODELS Repair procedures are identical to the preceding information on D-400 and D-600 series starters. It is A new starter assembly was introduced on 1976 models and will be furnished as a service necessary to allow.020-.030 clearance between the worm shaft and armature plate when reinstalling replacement. the starter. This assembly includes a new cup and pin and a plastic pulley half and worm shaft. The pinion gear retaining ring is located on the starter pin and secures the entire as-.sembly. NEW CUP AND PIN RETAINING RING GROOVE ON PIN PLATE NEW PUL PINION GEAR I NEW RETAINING RING SERVICE BULLETIN REFERENCES 7-9