Recoil Replacement (Clamshell Inverters)

Updated 2 years ago by Juan Velez

181108-60-50-1

This bulletin covers the following models: 100306,100414, 100402, 100565, All other Clamshell-Style Inverters

Please read the instructions carefully and completely before performing the service.

SAFETY WARNING

To reduce the risk of injury, user must read and understand the operator’s manual before using this product.
DO NOT make any adjustments to the generator without first stopping the engine and disconnecting the spark plug wire.
Burns from hot parts — let the engine cool completely before touching hot parts.
Injury from moving parts
To reduce the possibility of fire or explosion, be careful when working around gasoline. Keep cigarettes, sparks and flames away from all fuel‐related parts.

Remove a total of eight screws from the left and right cover assembly, and then take off the left and right cover assemblies. NOTE: There are two tapping screws at the bottom of the right panel side--remove them.
Visual
See below.
Remove all screws and bolts of the front cover/rear cover. Remove the snap spring under the fuel spill rubber. Lastly, remove the rear cover and the illuminator.
Visual
See below.
Pull out the fuel hose from the fuel switch and remove the fuel tank. (If the unit has a fuel level sensor, unplug the connector of the sensor.)
Visual
See below.
Remove the screws to take off the right cover. Remove the screws of the handle-oriented plate and have the recoil handle through the front over.
Visual
See below.
Pull out the fuel hose from the carburetor inlet nozzle to have the front cover move freely.
Visual
See below.
Unscrew the two bolts from the metal bracket. Unplug the connectors of the right panel and the controller module.
Visual
See below.
Unscrew the bolts of the recoil cover and remove the recoil assembly.
Visual
See below.
Put the new spring into the pulley if needed to replace a new spring.
Visual
See below.
Put the new rope into the pulley and secure it with a stop-knot. Next, rotate the rope clockwise (spring side towards you [about 3.5 turns]) until the rope aligns with the open slot on the outer edge of the pulley.
Visual
See below.
Apply lubricant or grease to the shaft of the recoil cover and insert the pulley to the recoil cover.
Visual
See below.
Pull the rope into the slot and take the loose part of the rope inside the pulley and rotate the pulley about three turns (counterclockwise) until the tension spring resists. Hold the pulley from reversing until the rope is ready to wind back onto the pulley. Feed the rope out to the hole of the recoil cover and pull it through the guide hole on the outside of the recoil cover. Place the guide plate/pull handle on the rope and secure it with a stop-knot.
Visual
See below.
Place the two detend springs as shown.
Visual
See below.
Place the two plastic detents into the spring positions with some lubricant. Note the detents must press the springs when installing.
Visual
See below.
Install the hoop onto the the plastic press plate, and put the plastic press plate onto the plastic detents. The salient of detents must snap into the guide slot of the press plate.
Visual
See below.
The bolt can have some locking glue; place the bolt into the through-hole of the press plate and tighten the bolt.
Visual
See below.
Secure a stop-knot at the end of the new recoil cover end.
Visual
See below.
Pull the rope out for some length and secure a stop-knot. Next, disassemble the oriented-plate from the old recoil assembly and install it to the new one.
Visual
See below.
Reinstall the recoil assembly with the tightening bolts. Have the recoil handle and oriented-plate through the front cover. Lastly, install the oriented-plate to the panel and tighten the screws.
Visual
See below.
Reinstall the metal bracket and plug in all the connectors.
Visual
See below.
Reinstall the fuel tank. Remember to plug the fuel hoses to the fuel switch side and the carburetor inlet nozzle side.
Visual
See below.
Reinstall the front cover, rear cover, and illuminator, and tighten the screws and bolts. Do not forget the tapping screws at the bottom and the snap spring.
Visual
See below.
Reinstall the left cover and the right cover with the screws.
Visual
See below.