Small Engines (Lawn Mowers, etc.): Kohler mower rope wont rewind, recoil starter, starter rope

Question
I have a Husqvana mower with a Kohler Courage XT-7 vertical crankshaft engine.  The starter rope broke.  I bought a new one and started following "how to" instructions I found in an article.  I removed the old rope.  The instructions then indicated that I should turn the pulley counter-clockwise to wind the spring before threading the new rope.  However, when I turn the pulley, there is no tension or recoil.  I went on and threaded the new rope and tried it ... of course when I pulled the rope, nothing happened, and the rope would not retract.  Can you tell me how to wind the spring?  I assume it must be wound before I thread the new rope on the pulley.

Thanks

Answer
Hello Charles:

>>From your Description it Sounds like the Recoil Spring Broke when it Back-lashed from the Rope Breaking and Requires Replacing also.
>>The Following is a Basic Horizontal Recoil Starter Repair Instruction File. Any Input/Suggestions are Appreciated. Remove the Starter Housing/Engine Cover. Remove the Old Rope (the Rope is Not Installed onto the Pulley Until AFTER the Spring and Pulley are Installed into the Housing. All will be explained later in these Instructions), Pulley and Spring from the Blower Housing. Clean the Housing. Now Take the New Spring and Locate the Housing Lock Hole that is Usually Near the Pull Handle Hole. Slip the New Spring Into this Hole and Lock the End Onto the Pulley. Now Lock the Pulley Into the Blower Housing. Turn the Pulley in the Same Direction that it would Turn During the Starting Process. The Spring will be Pulled Into the Blower Housing as you Turn the Pulley. When the Spring is Almost All the Way Into the Housing; Hold the End with Pliers and Make Sure it Catches in the Blower Housing Lock. Once the Spring is Locked Into the Housing, then Continue Turning the Pulley in the Same Direction that the Pulley would Turn if the Rope was Turning it. Once the Pulley will Turn No More, then Reverse Direction 1 or 2 Turns and Thread the New Rope Through the Hole in the Center of the Pulley and Out the Hole in the Blower Housing. Pull the Rope Through Until it is Tight Against the Pulley. Now Tie a Slip Knot in the Rope to Hold the Pulley in Place While the Handle is Attached to the Rope. Once the Handle is Attached, Release the Slip Knot and the Rope Should Retract Into the Housing. Reassemble the Blower Housing Onto the Engine. On Some Models you May have to Install the Rope Before you Lock the Pulley in Place. If So, there is a U in the Pulley that the Rope is Held in While Turning the Pulley to Tighten the Spring. These are for Most Recoil Starters. If these Instructions are Not for your Recoil Starter, then Send me the Model Numbers Off the Unit, Please. With these I can Locate the Proper Manual and Better Assist you.
>>You can View a Breakdown of the Engine at this Site Addy; http://www.kohlerplus.com/login.asp (IE5 or Higher Required) and Select Enter as Guest. Now Select the Thumbnail of the Engine Catalog you Wish to View.
>>You can View a Breakdown/IPL of this Engine at this Site Addy, http://www.smallenginepartswarehouse.com/parts.asp and Select the Shop Online Parts Look Up. Then Select the Model Tab. Then Select the OEM (Kohler) and Enter the Model and Spec Numbers (). Then Double Click on the Model in the Results Area. Now you can Select the Section of the Engine you Wish to View.
>>If you Hit a Snag or this Does Not Correct the Problem,  I Hope to be Here if You Require More Assistance. Hope this Helps. Let me Know What Happens, Please. May the All Mighty Bless You and Yours. Be Safe and Happy. Thanks.

Good Luck

Respectfully

John

PS: I am Allowed to Answer 5 Questions a Day. If you See I am Maxxed Out, then Try Submitting your Question at or Just After 8pm EST (US). My New Day Starts then. Comments and Ratings are Greatly Appreciated. Thanks.

Respectfully

John