When I tighten the pull start down the cord does not want to wind back up, and when I leave the screws a little loose they rattle out and other problems occur. I have tried jamming the knot on the string in as much as it will go but it still rubs and won't wind up. I'm not sure how to fix it. Any suggestions? Thanks.

Locktite the screws but dont do them in too tight.

Another good method is to use RTV sealant. You can apply a thin bead of this around the rim of the pullstart housing. When dry it will act as a spacer and a pressure sealant as you can also apply it to the exhaust manifold and coupler.

amec your post is simply dumb advice.

Savage545, you need to find out whats binding your p/s pulley when you tighten down your screws. My guess is something is not seated properly with the recoil spring. I have seen the spring not fully pushed down into the housing groove, which causes everything to bind once your p/s is installed and tightened

I've also seen the knot for the cord stick out too far and bind up the recoil.

By all means, find out what's wrong and fix it. Do not leave the screws loose, even with locktite. That's a horrible suggestion.

Thanks for the help guys. I'm on my 3rd or 4th pull start now, and even the brand new ones will bind if the screws are in too tight.[] Hopefully I will find the problem and fix it before another p/s breaks.

I would check to make sure the bearings are fully seated then. If you've been through 3 pullstarters it doesn't sound like that's the problem.

[:-]