

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.



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).

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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.


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!!


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.


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!!
With 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!!).


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.....
WARNING: 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!!


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).


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!


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