SUZUKI DT2.2 Recoil cord replacement .

[clyst]

Hi guys .
After some 20 years the cord on my trusty 2.2 decided to fail .Has anyone replaced the cord ? Having removed the recoil assy it appears to be held together by a single bolt ,now my question is if i remove the bolt am i going to get several feet of spring flying all over the place or is it a seal unit......... if that makes sense .

 

[Corribee Boy]

Any chance of posting a picture? I'm not familiar with that outboard, but there's sometimes a way to avoid having the spring decapitate you.

 

[VicS]

Hi guys .
After some 20 years the cord on my trusty 2.2 decided to fail .Has anyone replaced the cord ? Having removed the recoil assy it appears to be held together by a single bolt ,now my question is if i remove the bolt am i going to get several feet of spring flying all over the place or is it a seal unit......... if that makes sense .

See section 11 of the Suzuki manual on the boatinfo website

Boatinfo - Suzuki 1988-2003 Service Manual

 

[FairweatherDave]

I'm sure I have replaced my cord on my dt2.2. I don't remember it being at all complex. But possibly I had the advantage of the old cord being intact so I could see how it was supposed to run. Sorry I can't be more help, but I'm interested how you get on.

 

[duncan99210]

It’s not complex. Remove the bolt, lift the assembly out, remove the remains of the old cord, replace with new. However, be very, very careful not to release the return spring. It’ll skin you knuckles as it comes out and then you’ll spend an entertaining time getting it back into the housing: the first time I did it, it took me a couple of hours. And no, I can’t remember exactly how I managed it but the air was blue, my knuckles were bruised and cut and I was in a foul temper.

 

[clyst]

Thanks for all your replies . Now all done thanks .

 

[FairweatherDave]

Excellent. Obviously your knuckles are still intact

 

[GHA]

Bit late but thin dyneema works well for outboard pull cord, very chafe resistant.