BG56C Pull Start Assembly Issues (Fixing Stihl Blower Springs)
Imagine the frustration: You’re ready to tackle that pile of leaves, the Stihl BG56C blower is primed, but the pull cord refuses to budge, or worse, it pulls out limp and useless. It’s a common problem, and usually, the culprit is a broken or malfunctioning pull start assembly, specifically, those pesky springs. I’ve wrestled with countless pull starts over the years, from stubborn lawnmowers to temperamental chainsaws, and that’s why I’m here to guide you through fixing those Stihl blower springs and getting your BG56C back in action.
Understanding the BG56C Pull Start Assembly
Before diving into the repair, let’s understand what we’re dealing with. The pull start assembly, also known as the recoil starter, is a crucial component that initiates the engine. It consists of several key parts:
- Rope: The cord you pull to start the engine.
- Handle: The grip at the end of the rope.
- Pulley (or Spool): The rotating part that the rope winds around.
- Rewind Spring: The coiled spring that retracts the rope after you pull it.
- Pawls (or Dogs): Small pivoting levers that engage with the engine’s crankshaft to turn it over.
- Housing: The plastic or metal case that encloses all the components.
The rewind spring is the heart of the assembly. When you pull the rope, the pulley spins, and the rewind spring gets wound up. Once you release the rope, the spring unwinds, retracting the rope and handle back into the housing. A broken or weak rewind spring is the most frequent cause of pull start problems.
Common Issues with Stihl Blower Springs
I’ve seen it all, trust me. Here are the most common issues I’ve encountered with Stihl blower springs:
- Broken Spring: This is the most obvious problem. The spring snaps, usually due to fatigue or over-extension.
- Weak Spring: The spring loses its tension over time, resulting in slow or incomplete rope retraction.
- Dislodged Spring: The spring comes loose from its mounting points, preventing it from functioning correctly.
- Spring Corrosion: Rust and corrosion can weaken the spring and eventually cause it to break. This is more common in humid environments.
- Spring Binding: Debris or improper lubrication can cause the spring to bind, hindering its movement.
Tools and Materials Needed for the Repair
Before you start, gather the necessary tools and materials. Having everything on hand will make the repair process much smoother.
- Screwdrivers: A set of both Phillips head and flathead screwdrivers of various sizes.
- Pliers: Needle-nose pliers are particularly useful for manipulating small parts.
- Socket Set or Wrenches: To remove the pull start assembly from the blower.
- Work Gloves: Protect your hands from sharp edges and dirt.
- Safety Glasses: Essential for protecting your eyes from flying debris.
- Pick or Awl: Helpful for removing small parts and cleaning.
- Lubricant: A light oil or grease to lubricate the spring and other moving parts. I prefer using a silicone-based lubricant, as it doesn’t attract dust and grime.
- Replacement Spring: Purchase a new spring specifically designed for the Stihl BG56C. Make sure it’s a genuine Stihl part or a high-quality aftermarket equivalent.
- Clean Rag: To wipe away dirt and grease.
- Small Container: To hold screws and small parts.
- Camera or Smartphone: Take pictures as you disassemble the assembly to help you remember how everything goes back together.
- Work Surface: A clean, well-lit workbench.
Step-by-Step Guide to Fixing the Stihl BG56C Pull Start Assembly
Now, let’s get down to the nitty-gritty of repairing your Stihl BG56C pull start assembly.
Step 1: Removing the Pull Start Assembly
- Turn off the Blower: Ensure the blower is turned off and the spark plug is disconnected for safety.
- Locate the Pull Start Assembly: It’s usually located on the side of the engine, near the back.
- Remove the Housing Cover: Use a screwdriver to remove the screws holding the housing cover in place. Place the screws in your small container to avoid losing them.
- Detach the Pull Start Assembly: Carefully detach the pull start assembly from the engine. There may be screws or clips holding it in place. Again, store these fasteners securely.
Step 2: Disassembling the Pull Start Assembly
This is where the pictures you took earlier will come in handy.
- Secure the Pulley: Hold the pulley in place to prevent it from snapping back when you release the rope. You can use a vise with soft jaws or simply hold it firmly with your hand.
- Remove the Rope: Carefully unwind the rope from the pulley. Note how it’s routed through the handle and the housing.
- Release the Pulley: Slowly release the pulley, allowing it to unwind gradually. Be careful, as the spring is under tension and can cause injury if it snaps back suddenly.
- Separate the Housing: Separate the housing halves. This may require some gentle prying with a flathead screwdriver.
- Remove the Spring: Carefully remove the rewind spring from the housing. Note how it’s positioned and attached to the pulley and the housing. This is crucial for reassembly.
Step 3: Inspecting the Components
Now that the assembly is disassembled, inspect each component for damage or wear.
- Spring: Look for breaks, cracks, rust, or deformation. If the spring is broken or significantly weakened, it needs to be replaced.
- Pulley: Check for cracks, chips, or wear on the rope groove. A damaged pulley can cause the rope to fray or bind.
- Pawls: Inspect the pawls for wear or damage. These small levers are responsible for engaging the engine’s crankshaft. If they’re worn, they may not engage properly, preventing the engine from starting.
- Rope: Look for fraying, cuts, or wear. A damaged rope can break, leaving you stranded.
- Housing: Check for cracks or damage. A cracked housing can compromise the integrity of the assembly.
Step 4: Replacing or Repairing the Spring
If the spring is broken or weak, it needs to be replaced. If it’s simply dislodged, you can try to reattach it.
- Replacing the Spring:
- Clean the Housing: Clean the inside of the housing to remove any dirt or debris.
- Lubricate the Housing: Apply a light coat of lubricant to the inside of the housing to allow the spring to move freely.
- Install the New Spring: Carefully install the new spring into the housing, making sure it’s properly seated in its mounting points.
- Attach the Spring to the Pulley: Attach the other end of the spring to the pulley, following the original configuration.
- Reattaching a Dislodged Spring:
- Inspect the Mounting Points: Check the mounting points on the housing and the pulley for damage.
- Clean the Spring: Clean the spring to remove any dirt or debris.
- Reattach the Spring: Carefully reattach the spring to its mounting points, ensuring it’s securely in place.
Step 5: Reassembling the Pull Start Assembly
Now it’s time to put everything back together.
- Position the Pulley: Place the pulley back into the housing, aligning it with the spring.
- Pre-Wind the Spring: This is a critical step. You need to pre-wind the spring to create the tension necessary for retracting the rope. The number of turns required will vary depending on the specific model, but a general guideline is 3-5 turns.
- Hold the Pulley: Hold the pulley in place with one hand.
- Wind the Pulley: Use your other hand to wind the pulley in the direction that tightens the spring.
- Secure the Pulley: Once you’ve pre-wound the spring, secure the pulley to prevent it from unwinding.
- Install the Rope: Thread the rope through the hole in the pulley and tie a knot at the end to secure it. Then, thread the rope through the housing and the handle.
- Test the Retraction: Release the pulley and test the retraction. The rope should retract smoothly and completely. If it doesn’t, you may need to adjust the pre-wind.
- Reassemble the Housing: Reassemble the housing halves, making sure all the components are properly aligned.
- Secure the Housing: Secure the housing with the screws you removed earlier.
Step 6: Reinstalling the Pull Start Assembly
- Attach the Assembly: Attach the pull start assembly back to the engine, using the screws or clips you removed earlier.
- Install the Housing Cover: Install the housing cover and secure it with the screws.
- Reconnect the Spark Plug: Reconnect the spark plug.
Step 7: Testing the Blower
- Prime the Engine: Prime the engine according to the manufacturer’s instructions.
- Start the Blower: Pull the starter rope to start the blower. If everything is working correctly, the engine should start easily.
- Check the Retraction: After starting the blower, check the rope retraction again to ensure it’s still working properly.
Troubleshooting Common Problems
Even with careful attention to detail, you might encounter some issues during the repair process. Here are some common problems and how to troubleshoot them:
- Rope Won’t Retract:
- Insufficient Pre-Wind: Increase the number of pre-wind turns.
- Weak Spring: Replace the spring.
- Binding: Check for debris or improper lubrication.
- Rope Retracts Too Slowly:
- Weak Spring: Replace the spring.
- Binding: Check for debris or improper lubrication.
- Engine Won’t Start:
- Pawls Not Engaging: Inspect the pawls for wear or damage.
- Incorrect Rope Routing: Ensure the rope is routed correctly through the pulley and the housing.
- Spring Keeps Breaking:
- Low-Quality Spring: Use a genuine Stihl part or a high-quality aftermarket equivalent.
- Over-Extension: Avoid pulling the rope out too far.
Preventing Future Problems
Prevention is always better than cure. Here are some tips to prevent future problems with your Stihl BG56C pull start assembly:
- Proper Maintenance: Regularly inspect the pull start assembly for signs of wear or damage.
- Lubrication: Lubricate the spring and other moving parts periodically.
- Avoid Over-Extension: Don’t pull the rope out too far, as this can over-stress the spring.
- Proper Storage: Store the blower in a dry place to prevent corrosion.
- Use Quality Parts: When replacing parts, use genuine Stihl parts or high-quality aftermarket equivalents.
Alternative Solutions
If you’re not comfortable repairing the pull start assembly yourself, there are alternative solutions:
- Professional Repair: Take the blower to a qualified repair shop. They have the expertise and tools to diagnose and repair the problem quickly and efficiently.
- Replace the Entire Assembly: You can purchase a complete pull start assembly and replace the entire unit. This is a relatively simple procedure that can save you time and effort.
Case Studies and Real-World Examples
I had a customer, let’s call him Bob, who brought in his Stihl BG56C with a completely shredded pull start rope. Upon inspection, I found that the pulley had a sharp edge that was causing the rope to fray. I replaced the pulley and the rope, and the blower was back in action. This highlights the importance of inspecting all the components of the pull start assembly, not just the spring.
Another time, I encountered a BG56C where the spring was constantly breaking. After some investigation, I discovered that the customer was using a low-quality aftermarket spring. I replaced it with a genuine Stihl spring, and the problem was solved. This underscores the importance of using quality parts.
Advanced Techniques and Modifications
For those who are more experienced, there are some advanced techniques and modifications you can consider:
- Upgrading the Spring: You can upgrade to a heavier-duty spring for increased durability.
- Installing a Roller Bearing: Installing a roller bearing on the pulley can reduce friction and improve rope retraction.
- Customizing the Handle: You can customize the handle for a more comfortable grip.
Safety Precautions
Safety should always be your top priority when working with tools and machinery. Here are some safety precautions to keep in mind:
- Disconnect the Spark Plug: Always disconnect the spark plug before working on the blower to prevent accidental starting.
- Wear Safety Glasses: Wear safety glasses to protect your eyes from flying debris.
- Wear Work Gloves: Wear work gloves to protect your hands from sharp edges and dirt.
- Work in a Well-Lit Area: Work in a well-lit area to avoid accidents.
- Use the Right Tools: Use the right tools for the job to avoid damaging the blower or injuring yourself.
- Be Careful with the Spring: The rewind spring is under tension and can cause injury if it snaps back suddenly.
- Read the Manual: Read the manufacturer’s manual before working on the blower.
Conclusion
Fixing a Stihl BG56C pull start assembly, especially dealing with those troublesome springs, might seem daunting at first. But, with a little patience, the right tools, and this guide, you can tackle it yourself and save some money. Remember to prioritize safety, take your time, and don’t hesitate to seek professional help if you’re unsure about any step. Now go forth and conquer those leaves!
