Cord seems to be slipping off the flywheel; I pull and the cord goes slack, spools out much more than is needed, and when it retracts (basically from my stopping the pull and slowly letting it reel itself in) there a chattering sound.

Hi Barbara:
The pull start assembly is usually attached by 3 or 4 bolts.
Start by removing it. Depending on where the pull cord broke, you may be able to use it shortened a bit, but replacement is probably a good idea.
There is a spring inside the thing the cord winds around (spool)that retracts it after you've pulled on it. The tricky part is making sure that the spring is wound up enough after you've installed the replacement cord.
Look at the way the old cord is installed. If you can, grab it with some pointy pliers and pull it all the way out, winding up the spring tension at the same time. There should be a way to hold the spool (look for a hole you can slip the end of a nail into) so you can change the cord. Then Take the nail out and make sure the cord retracts all the way.
Next step is to re-install it on the mower.
Cheerfuls!

-Need to rewind little more on the pull rope assembly.


Good luck

Mai

Ok, the spring will more than likely unravel when you remove the pull cord cover/assembly. There is notch in the spool for winding the rope around it. So make sure the spring is wound enough to fit it in the housing. Then take the rope, already knotted and in the spool. Turn the spool in the direction that tightens the spring.Push down on spool and allow spring to retract the rope. (Don't forget to tie the knot in the rope handle before placing on mower). Then lightly clamp in vise or visegrip, or channel lock pliers. I like to use visegrips on one side, and channel locks on the other. Place over the square flywheel nut,release channelock pliers, hold with fingers tightly so the spring does not unravel. Then release visegrips and hold with other free hand, Place over flywheel nut and slide down. Re-attach with screw previously removed. Your done. Don't forget to tie the knot in the rope handle before placing on mower.

check this link out it will show you http://www.youtube.com/watch?v=CTCEJ3hTSOQ

The piece on the recoil that engages with the fingers on the flywheel is worn. You have to get another spool that goes in to the recoil it is usually plastic and it wears.

Remove the starter assembly from the side of the engine. Remove the balance of the old cord from the spool and purchase about 1-meter of replacement cord from a saw shop (it should be nylon, not cotton). Insert the new cord into the center slot/hole in the spool, melt the end, and tie an overhand knot. Wind the cord around the spool several turns in the same direction as the old cord, then pull on the cord to wind the return spring inside the spool. Wedge the spool to prevent rewinding, then continue to wind the cord until about 8-10 inches are left. Feed the cord end through the cord port and into the handle. Melt the cord end, then tie an overhand knot and pull the knot back into the cavity in the handle. Remove the spool wedge and test the pull of the cord--it should pull out smoothly and return fully without slack. Hope this helps!

Remove the starter assembly from the engine and pull the cord out--it should have spring resistance to pulling. If nothing, the rewind spring may be broken, or it may have pulled loose from one of the attachment points. Remove the cord from the pull handle and unwind it from the spool if it isn't already pulled out. Remove the spool from the frame to expose the spring--check the ends for breakage and the attachment points for damage (one will be on the under side of the spool). Repair or replace any damaged components and assemble the spring into the attachments. Wind the spool/spring about 2-turns CW, then wedge it to prevent unwinding. Fit the cord back into the spool and wind it CW until the cord has about 8" or so to feed out through the cord port. Fit the cord end back into the handle, tie an overhand knot, and push the knot into the handle bore. Remove the spool wedge and try pulling the cord several times to make sure it goes out and back smoothly. Return the starter to the engine and attempt starting. Hope this helps!

I assume you are speaking of the starter cord return spring. Make sure to turn it CCW to wind it, but leave enough slack so that the spool can turn about four more turns without binding the spring when starting. If the cord broke, the spool may have over-run it's stops--try to to pull the spool outward when trying to wind the spring. Leave the cord off until you get the spring correctly wound. When wound, wedge the spool to prevent it from unwinding. Be sure to melt the cord ends before tying the overhand knot--but leave the outer end alone until the handle is slipped over the cord. Hope some of this helps!

try pushing the cord back in whilst depressing the retract button

these usually are threaded counter clockwise need a pair of channel locks to hold the flywheel then with the other hand crack nut open