August 25, 1961
Bulletin No. SB-864
Manual Starters
SUBJECT: Change in servicing nylon starter ropes;
All engine models from 1956 thru current & future models.
As soon as distributors' stocks of current starter ropes are exhausted, only two basic
ropes will be serviced. These two ropes are part numbers 204085 (7/32" diameter) and
203819 (5/32" diameter), from which all starter ropes for the various engine models must
be made by cutting them to the required length specified in the following table.
7/32" Diameter Ropes
TO MAKE CUT #204085 to
ROPE NO. LENGTH SHOWN
204085 75 3/4" (Basic rope)
203821 72 1/4"
203822 70 3/16"
304096 69 3/4"
305000 73 3/4"
5/32" Diameter Ropes
TO MAKE CUT #203819 TO
ROPE NO. LENGTH SHOWN
203819 71 1/2" (Basic Rope)
203817 68 5/16"
203818 66 3/4"
203820 70"
304097 63 3/4"
After the rope has been cut to the correct length, the cut end must be singed to prevent
fraying by gently applying heat around the circumference with a lighter or match.
The timing of the starter is affected by the placement of the knot at the end of the rope
as well as by the rope's length. When the rope is cut to the required length shown and
the knot is placed 1/2" from the end (1/2" of rope protruding from knot), the starter is
correctly timed. This can be checked by aligning the correct timing marks.
If for some reason the cutting length of a given rope is not available, proceed as follows:
Install the rope as usual to the point of having the handle on the rope. Let the
starter rewind until the timing marks are in alignment and put a knot in the rope
so it won't pull through the handle. Allow enough rope to thread the anchor; then
cut to the required length, singe the cut end, remove the knot and thread the
anchor. The timing should be correct when the anchor is placed in the handle.
Past parts catalogs specify one of the old rope numbers for a given engine model. To
determine which of the two (2) basic ropes to use when replacing a starter rope, refer to
the appropriate parts catalog for the engine being serviced, and note the rope number
specified. Then refer to the table contained in this bulletin to determine which basic
rope to use and the length to which it must be cut.
The 1962 Master Parts Price list will also contain the table shown in this bulletin. After
these price lists are received by you, reference should be made to it to determine the
basic rope to use and the proper length to which it must be cut.
Future parts catalogs, instead of specifying the old rope numbers, will specify one of the
two (2) basic rope numbers along with the correct length.
JOHNSON MOTORS
W. W. DeWees
Service Department
WWD:eb
NOTE: Post on all indexes, JW thru V-75