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Recoil starting problems with 5269D Lawnboy

1404 Views 12 Replies 4 Participants Last post by  RfWi
Hello - ever since I picked up this model 5269D White top Lawnboy it's had, what I considered an extremely short rope pull. The other Lawnboys that I run have a longer rope, but since the 5269D always started Ok - I just left it alone. A few weeks ago I was showing it off to my BIL and when I pulled it over it just slipped and didn't engage. It recoiled fine, but I could only get to engage about every fourth time or so, or if I changed the angle of my pull. I removed the recoil assembly and checked the plastic gear and the spring clip on the shaft all held on by an E clip. Since I don't really know what I'm looking at, is it possible that the plastic gear on the spiral shaft is worn and is slipping or something more involved? I would also like to get the correct diameter and length of pull rope. The spring tension appears to be OK - so I don't believe the spring is broken.


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I've gotten everything cleaned up - it wasn't too bad. I really don't know the difference but the starter pinion feels really sloppy on the spiral shaft. Since I have it apart - I ordered the eBay #4 starter rope that you linked too and the following:

604260 Starter Clip
607547 Starter Pinion
609005 Washer

Of course when I was playing around with everything I unraveled the spring in the recoil, so I get to fiddle around with that when the balance of the parts get here.
Thank you for the pdf. That is the 604260 Starter Clip you are describing that I ordered. I'm printing it out now and hanging in it in protective sheets in the pole barn. I'll bet my problem is the gap on the spring clip as mine is at least 3/4". I also believe it was installed incorrectly as well. Thanks to all for the advice - I'll be sure to post back and give an update. We had over 4" of rain this past week in NW PA - if it ever dries out we'll be mowing alot.
That's crazy. We sure have had some wet weather in 2018 and continuing now well into 2019. 2018 precipitation amounts in Clearfield County, PA averaged 82 inches - we normally get around half of that. Even the "old-timers" around here can't remember such a severe and prolonged wet spell. Stay high and dry.
Just a delay in the repair here. During my muddling - I managed to break off the little tab on the aluminum recoil plate that retains the circle end of the spring. I have another NOS part to be delivered today and also got a new Stens Lawnboy recoil spring. Does anyone have a picture or service manual page that shows the proper way to fit the end of the spring into the recoil plate?
Nevermind - it is included in the PDF that RfWi was kind enough to link for me. Sorry for the bother. Guess I need to slow down a little bit?
It cranks!

Since I last posted (not counting my senior moment this morning), I managed to snap off the aluminum tab that holds the coiled spring during a trial "wind the spring, wind the rope and crank the mower" session. I still have no idea how I did it? I ordered a new aluminum shaft plate and recoil spring. As soon as the mail lady was headed down the road this afternoon - I was headed to the shop with my collection of new parts. I'm relieved to say that the re-install was pretty straight forward, although I did carry on quite a conversation with myself during the process. It now cranks smooth and catches the flywheel every time - like it's supposed to. In addition to my new Lawnboy parts - I also ended up with 3 rolls of new starter rope - all Stens. But the best part is that I also learned about and repaired something and that ALWAYS feels good.

The advice, suggestions, and reference help from you fellow Lawnboy lovers really made the difference and I'm very grateful to all of you. Thank you - until next time.
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