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Starter Cord Nightmare General Info

Cord Snag !!!

If your Powerball is suffering from this condition, even after much persuasion and gentle tugging, the starter cord refusing to budge?.....

Follow these instructions to open your Powerball and retrieve a trapped starter cord, or anything else that refuses to relinquish it's new hiding place in your precious sphere.

Band offRemove the rubber band (grip) from the Powerball.

With the band removed, examine the groove all around the surface of the Powerball. You will see two screws at opposite sides holding down what look like plastic 'tabs' - these are part of the shell, do not lift them!

Both screws must be removed using a small 'star'/philips screwdriver. Put them in a safe place until you're ready to screw them back in. Please do not lift the plastic 'tabs' they no longer have anything to do with keeping the shells together..... the screws are already out.

Remove both screwsScrewsScrews out

In the next step you will pop your Powerball open. Using the picture below-left as a reference, the Powerball is aligned so that the screw holes are on the left and right (where the red arrows are pointing). Make sure the direction of the groove in the rotor is about 45-degrees (AS PER THE PICTURE).

Popping it open !!Distinct POP!

By applying inward pressure at opposite sides of the Powerball (in the area of screw-holes) as indicated by the red arrows, to  squeeze these sides towards each other  so that the Powerball  distorts inward by the yellow arrows  and  distorts outward by the green arrows  until one of the sides indicated by the green arrows literally 'pops' open!!

A similar trick can be done by placing a book (instead of a knee) over the Powerball and then standing or sitting on it, bouncing your body weight on it. Listen for (or feel) the 'pop', making sure the Powerball is positioned correctly between attempts.

The best tool to use is a vice, but make sure you put enough cloth or wood between the jaws of the vice and your Powerball to prevent scratches while it gets the squeeze of its life.

Snap lock

All Powerballs are difficult to 'pop' for the first time. The reason for this is the 'freshness' of the snap-lock mechanism that keeps the shells together, indicated by the blue arrows in this picture.

After popping the shells open, pry them apart with your hands.... Don't be too hasty though and make sure you work over, or close to something that will catch any flying pieces....

If you're still struggling..... then put it through another squeezing.

With the shells apart, things are looking promising ....... You can try freeing the cord without removing the white stabiliser ring from the yellow rotor...... or, while you're here you can learn something more about your Powerball. At this stage you can already do a basic clean and service on all the parts that make the Powerball work.

Opened !!Exposed Stuck Cord

If your cord has really worked itself into the rotor you'll need to remove the white ring (or stabiliser ring).

Stabiliser Ring and WashersATTENTION! - small washers on the inside of the ring will fall out during the next procedure, work over something to catch them!! If they don't fall out then look for them...... they must be there !! There are a total of three washers (picture right - blue arrows), two square and one round.

To remove the white Stabiliser Ring, observe the metal points protruding through the ring at opposite ends (picture below right - blue arrow), this is the rotor's axle!. Lift one side of the ring up (as indicated by the red arrows) and then over the axle. Now gently pull the ring off the other end of the axle to separate the two completely. A certain amount of gentle twisting/flexing on the ring will be required - this is normal.

Stabiliser Ring removalSupport band Up and Over the axle

This now leaves the rotor completely exposed for you to easily remove the trapped starter cord. The whole ordeal having quite a negative impact to the twisted starter cord, but a few straightening tugs will bring it back to normal quickly.

Starter Cord ExposedCord free !!Rotor free !!

And that's it !!! - you've learnt how to open the Powerball and separate the individual components. Useful for removing starter cords and foreign obects, servicing or repairs.

Now the trickiest part of all, getting it all back together. Simply follow the remainder of these instructions carefully and your Powerball will be back to the the way it was just before the mishap.

GETTING IT BACK TOGETHER......

A note on preparation.... you may want to take the opportunity to inspect and clean the individual components before reassembly. If you're using soap and water make sure you rinse and dry properly, otherwise a mild solvent such as alcohol will be fine. NEVER LUBRICATE ANYTHING !!! - this is a Powerball's worst enemy and WILL STOP IT WORKING ALTOGETHER - requiring a thorough clean/service to get it going again.

When you're ready to start the reassembly process make sure you still have all three washers and both screws. The washers go back in the following order (picture below left), and in relation to the rotor (picture below right).

Washer placementWasher Sequence

Starting with the big-end of the white ring (the side with the metal piece attached) .... Orientate the rotor so that the correct axle is facing upward (i.e. opposite to gravity). Place washer number 2 onto the axle first, and washer number 1 last. Then, carefully guide the big-end of the ring over the washers, taking care not to bump them off the axle - note that the big-end has a square hole, hence the square washer. You could try the alternative of dropping the washers into the hole and sending the axle in after them, just get the washer sequence right, number 1 being the first one in, and make sure they're lying flat against the little hole at the end. In any case, the end of the axle needs to protrude at the other side of the ring (through the little hole, like it was before you took it apart). Some gentle twisting/flexing of the white ring will be required - this is normal.

Ring and Washer Close upWashers on Rotor

Pictured below-left, and Flipped over (big-end at the bottom) this is what you should see now..... with half the white ring on, ready for washer number 3... do it!!

Support Band on one SideWasher on Rotor

To get the white ring back onto its original position (i.e. axle through the hole!). With reference to the picture below-left, simply lift the white ring (red arrow) and position it (orange arrows) over the axle (blue arrow) to align with the small hole (for the axle!!)..... relax... and you're done!! The image below-right is what you should see.

Stabiliser Ring final stepStabiliser Ring Fitted

This'll be a good time to check your handywork and immediate surroundings for any stray washers maybe ? Once you're satisfied, move on... otherwise redo it if you have the slightest doubt. The last thing you want to hear is a washer being munched while you're winding the rotor just past 12K!!

Ready for ReassemblyWith the trickiest part out of the way!.... Now moving onto the final assembly! Take one of the plastic shells and place the rotor assembly into the shell cavity, making sure that the rotor axle is placed properly on the 'track' on the inner-edge of the shell indicated by the blue arrows in both images below. It doesn't matter which way around the rotor goes in, as long as its a good fit (only exception being the TECHNO Powerball - we'll cover that one later!!).

Rotor on trackTrack One Side

Place the other shell over the rotor so that the two shells meet each other perfectly all the way round and that the 'tabs' line up like they should. At this stage (as long as you keep the shells together) the rotor assembly is quite well positioned and secure for you to move the Powerball into the best location for the next step.

THE LAST FEW STEPS, CLOSING UP.....

OUCH !!! Do not kill itWARNING:  The next procedure requires a fair amount of pressure to 'snap' the shells back together. Please DO NOT APPLY ANY PRESSURE TO THE ROTOR in the process !! doing so (especially in a vice) will spell THE END OF YOUR POWERBALL...... PERMANENTLY !!

Now, ready to be snapped-shut... the Powerball (picture below-left) is laying on its side. The large red arrows represent the equal amount of liberal pressure required to force the two shells together, and the yellow arrows representing the action of the snap-lock mechanism (all the way around the edges of both shells). Only when enough pressure is being applied, will the two shells suddenly 'snap' together!!

Snapping it closedSnap Closed

You're almost home and dry! You can even give your Powerball a quick spin to satisfy your curiosity.

Now simply replace the two screws.... not tight!.... And before replacing the rubber band (grip) take note of the raised ridge on the inside of the band - this 'slots' into the groove around the Powerball (where the two shells meet).

 Screws back inGrip Band Ridge and Groove

If the ridge has not aligned with the groove you'll notice bumps or bulges on the surface of the band (picture below-left, blue arrows), slide the band as indicated by the red arrows until you find the groove, wiggle the band a bit over the area for a perfect fit!

Band alignmentBand Fitted

That's it....DONE! Start it up and take it for a spin...

 

For further assistance, queries or suggestions regarding this document, the procedure, or our website,  please use our feedback or contact facilities.

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