Cummins/Onan 205AJ — Recoil starter installation
Installation
For the Cummins/Onan 205AJ, from the Cummins/Onan operator's manual.
Applies to: Cummins/Onan AJ series
Before you start
- Failure to center starter properly will damage starter.
Procedure
- Remove existing rope sheave from engine flywheel; reuse flat washer and lock washer.
- Secure cup using lock washer and flat washer between cup and cap screw.
- Assemble mounting ring to starter with four screws in desired rope-pull position.
- Place three U-shaped speed nuts on engine housing.
- Place starter against blower housing; check centering pin engages cup-and-flywheel capscrew center hole.
- Use three sheet metal screws to mount starter securely.
- Check approximately 1/8 in clearance between cup and rotor face and minimum 3/32 in between capscrew and starter shaft.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Cup-to-rotor face clearance approximately 1/8 in
- Minimum capscrew-to-starter-shaft clearance 3/32 in
Full service-parts list: Cummins/Onan AJ series →
Source: Cummins/Onan operator's manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.