Yamaha 25hp recoil start reference

Huntindave McCann

Well-known member
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Posting this just for reference in case anyone finds it useful. A partial explanation of the rope start recoil mechanism as it pertains to the neutral lock and the engagement pawl.

The entire assembly is removed from the engine by removing these 3 bolts;
PIN_004.jpg

If desired ( to allow more working room or to move the assembly to a bench) the "cable end" can be removed by backing off this nylon nut until it is completely free of the threads. At which point the nut, the cable, the spring, and the pin will slide free of the casting.
PIN_003.jpg

How the neutral safety lock out works:
When in "neutral" the pin is retracted.
When in gear (Forward or Reverser) the pin is extended. Effectively blocking the rope pulley from rotating.
PIN_001.jpg
PIN_002.jpg
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How the rope start engages the flywheel hub;
A moveable pawl engages one of these 4 indents in the hub.
PIN_005.jpg

Movement of said pawl is controlled by a yoke which rides in a groove on stationary (non-rotating) pivot point.
PIN_006.jpg
PIN_007.jpg


Short video link;
 
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Excellent tips... I remember being stuck out on the bay a few years ago in my 14 TDB Classic with a 2007 25... Yamaha felt it was a brilliant idea to make that tab PLASTIC... was out there in less than ideal conditions and had the engage mechanism snap therefore pulling the rope was useless. I spent hours taking it apart and wrapping the recoil rope around that flywheel manually. Took sometime but made it out! Great motors but mannnn... definitely not thought out for a waterfowler part is $12 good idea to keep another in the boat LOL


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