STARTER DISASSEMBLY Remove retainer ring, pinion stop washer, pinion spring and pinion gear from helix. Remove starter pulley and spring. USE CAUTION WHEN REMOVING SPRING. Remove three screws holding the cup assembly to the starter motor. Remove cup. Remove motor pinion, starter gear and thrust washer. 85204 SAFETY WARNING TO PREVENT STARTER SPRING FROM UNWINDING HOLD PULLEY TIGHT AGAINST SPRING AND CUP. Remove clutch assembly. Remove retaining ring securing drag spring and drag roller to bracket. Remove roller and spring. When reinstalling drag spring place hook in end of spring through hole located in bracket, this correctly positions drag spring allowing correct pinion engagement when mower is manually started. Check all of the parts removed for any damage or wear. Examine rewind spring carefully for bent or weakened areas. Spring steel is quite brittle and is damaged easily if bent or twisted. A light coating of Lawn-Boy A grease must be applied before reinstalling. Replace any of the parts that are worn or damaged. r PIN AND CUP PINION PINION SCREWS ASSEMBLY STOP PINION STARTER GEAR MOTOR PINION STARTER SERVICE BULLETIN REFERENCES 7-13
STARTERASSEMBLY Install motor pinion gear onto short (small) motor shaft. Install thrust washer onto long motor shaft. Install large gear onto motor shaft, Lubricate both gears with Lawn-Boy A grease. Assemble cup to motor securing it with three cap screws removed in disassembly. Install rewind spring onto pulley as described on page 7-3 for the manual starter. Position pulley and spring on motor bracket pin locating spring in cup. x Do not attempt to rewind spring this time. at Install clutch assembly, pinion, pinion spring, stop washer and retaining ring. With motor shaft facing you, turn starter pulley clockwise pulling rewind spring into cup. Wind rope into pulley clockwise. Place 1/2 1-1/2 turns tension clockwiseonrewind spring. Tie a slip knot in rope permitting to stop behind rope retainer.
Assemble starter on Engine. : Be sure to place.020-.030 gap between end of (worm helix gear) and crankcase. I Reconnect all leads starter motor, alternator, key switch cable and battery. Check starter operation electrically. TROUBLE SHOOTING THE F ENGINE ELECTRIC STARTER The pinion gear on the electric start models of the F engine is activated by inertia. Manual starter engagement is accomplished by a typical pull through of the starter rope. 2. If starter engages manually, but not electrically (starter motor running), there may be a failure of the metal gears inside gear housing. (Replace broken gear as a set.) Gear Part Numbers are 608034.- and 610255. 3. If electric motor does not turn at all, check for electrical malfunction or for proper interlock adjustment. 4. After the motor starts, pinion should return to a position near the center of the helix---it should not touch teeth on flywheel, otherwise damage to pinion could occur. 5. Exercise electric start and manual start (actually starting the motor) several times each way before returning mower to service. SERVICE BULLETIN REFERENCES 7-15
ELECTRIC STARTER REMOVAL Remove shroud and air baffle. Set the alternator air gap. The correct air gap is.010 Position the air gap gauge, part no. 604659, in the gap between the alternator and flywheel. Loosen two cap screws securing the alternator. Rotate flywheel; when flywheel magnets are adjacent to the alternator they will pull it in tightly. Secure alternator with the two cap screws. Do not push or pull alternator or flywheel when adjusting. Disconnect leads from battery, motor and alternator. curing interlock mechanism frame. starter Remove screws seto starter 7-24 SERVICE BULLETIN REFERENCES
Loosen set screw holding starter motor shaft to crankcase cover. Remove hex cap screws securing starter motor bracket to muffler plate. Additional allen wrench clearance can be gained by removing carburetor. Remove hex cap screws securing starter motor bracket to starter frame. Do not try to move starter laterally to either the right or left. It is possible to bend the starter motor shaft. Carefully slide starter motor and bracket straight out from engine and lift out. The starter motor shaft locates and operates in a loose bushing located in the crankcase casting. This bushing is loose fit into the crankcase. This bushing can slide out and become lost when removing the starter. Check this bushing for wear and damage while the starter is out. SAFETY WARNING WITH THE STARTER ASSEMBLY REMOVED, IT IS POSSIBLE FOR CLUTCH AND ROPE PULLEY AS- SEMBLIES TO SLIDE OUT PERMIT- TING STARTER SPRING TO BE RE- LEASED ACCIDENTLY. HANDLE WITH CARE AND FOLLOW DISAS- SEMBLY PROCEDURES CLOSELY. SERVICE BULLETIN REFERENCES 7-25