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The Stihl 044 starter rope stiff /Pawlsor slowly repair guide

If the action of the Stihl 044 starter rope becomes very stiff and the rope rewinds very slowly or nor completely, it can be assumed that the starter mechanism is in order but plugged with dirt. At very low outside temperatures the lubricating oil on the rewind spring may thicken and cause the spring windings to stick together. This has a detrimental effect on the function of the starter mechanism. In such a case it is sufficient to apply a few drops of paraffin (kerosine) to the rewind spring.

Then carefully pull out the starter rope several times and allow it to rewind until its normal smooth action is restored.

If clogged with dirt or pitch, the entire starter mechanism, including the rewind spring, must be removed and disassembled. Take special care when removing the spring.

Wash all parts in paraffin or white spirit. Lubricate the rewind spring and starter post with STIHL low temperature lubricant, see A, before installing.

A: Servicing Aids

No. Part Name Part No. Application
1 Lubricating grease 0781 120 1111 Oil seals, oil pump drive, chain sprocket bearing
2 Medium-strength threadlocking fluid 0786 111 1101 Securing screws, see 1.6. Ignition module mounting screws
3 High-strength threadlocking fluid 0786 111 1109 Securing screws,  Fastening screws on choke and throttle shutters
4 High-strength threadlocking 0786 111 1117 Securing screws,
5 I Standard commercial, solventbased degreasant containing no CFCs Cleaning crankshaft stub
6 Sealant 0783 810 1101 Manifold, crankcase gasket
7 STIHL low temperature lubricant 0781 417 1315 Bearing bore in rope rotor, rewind spring in starter
8 Ignition lead HTR, 10 m (33″) 0000 930 2251

1. Removing rope rotor

Troubleshooting chart – see B.

B. Rewind Starter

Condition Cause Remedy
Starter rope broken Rope pulled out too vigorously as far as stop or over edge – i.e. not vertically Fit new starter rope
Normal wear Fit new starter rope
Rewind spring broken Spring overtensioned – no reserve when rope is fully extended Fit new rewind spring
Heavily soiled or corroded Fit new rewind spring
Starter rope can be pulled out almost without resistance (crankshaft does not turn) Guide pegs on pawls or pawls themselves are worn Fit new pawls
Spring clip fatigued Fit new spring clip
Starter rope is difficult to pull and rewinds very slowly Starter mechanism is very dirty (dusty conditions) Thoroughly clean complete starter mechanism
Lubricating oil on rewind spring becomes viscous at very low outside temperatures (spring wind­ings stick together) Apply a few drops of kerosine (paraffin) to spring, then pull rope carefully several times until normal action is restored

 

Starter rope is difficult to pull and rewinds very slowly Starter mechanism is very dirty (dusty conditions) Thoroughly clean complete starter mechanism
Lubricating oil on rewind spring becomes viscous at very low outside temperatures (spring wind­ings stick together) Apply a few drops of kerosine (paraffin) to spring, then pull rope carefully several times until normal action is restored

The fan housing has to be removed for access to the starter mechanism .

Relieve tension of rewind spring:

– Pull out the starter rope to a length of approx. 30 cm (1 ft) and hold the rope rotor steady.

– Use a screwdriver to catch the starter rope between the rope guide bush and the rope rotor.

– While still holding the rope rotor steady, take three full turns off the rope rotor.

– Pull out the rope with the starter grip and then let go of the rope rotor.

Note: The rope rotor will spin back and thus relieve the tension on the rewind spring. The rewind spring will not be under tension if the starter rope is broken.

– Use a screwdriver or suitable pair of pliers to carefully remove the spring clip from the starter post.

– Take the washer and rope rotor with pawls off the starter post.

– Remove the pawls and check to see if they are in good condition, replace if necessary. – Replace the broken or worn starter rope .

2. Installing the rope rotor

– Coat the bore in the rope rotor with STIHL low temperature lubricate. Fit the rotor on the starter post so thatthe inner spring loop slides into the lug on the rotor.

Note: Check that the spring loop has engaged by turning the rope rotor slightly and letting it go – it must spring back.

– Fit the pawls.
– Fit the washer and install the spring clip in the starter post groove.

Note: Make sure the spring clip engages on the pawl guide pegs and points them in the clockwise direction.

– The spring clip must be treated very carefully. If it is bent during disassembly or assembly, the rewind starter might malfunction.

– Tension the rewind spring.

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