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Service Manual 25-30 HP E-TEC Manual Starter [Pulley Modification]

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Service Manual 25-30 HP E-TEC Manual Starter [Pulley Modification]
5007802
BRP Marine

PULLEY MODIFICATION

Some early production models were assembled without a hole in the pulley for use with the stop tool from Starter Spring Winder and Installer, P/N 342682.

If necessary, use the one of the following procedures to add a hole in the pulley for before using the tool.

Starter Assembled Method

Use this method if the starter is completely assembled.

Pull the starter rope out completely. Wrap the rope from the pulley around the starter mounting boss two times and secure with a knot.

Make sure the pulley rope channel is aligned with the rope guide as shown.

  1. Rope channel
  2. Rope guide

Turn starter assembly over. Use an appropriate tool to push the shield toward the center of the pulley.

  1. Shield

Mark the pulley 7/8 in. (22 mm) from the inner edge of the opening. Drill a 7/32 in. (5.5 mm) hole through the pulley in this location.

  1. Mark
  2. Edge

Starter Disassembled Method

Use this method if the starter rope or spring is damaged, or if the starter is to be disassembled. Mark the pulley 1/4 in. (6 mm) from the inside edge of the pulley, and 7/16 in (11 mm) from the edge of the pulley rib as shown.

Drill a 7/32 in. (5.5 mm) hole through the pulley in this location.

  1. Pulley inside edge
  2. Rib
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