Ok, got it back together with the new nylon rope on it!!!! :thumbsup: I have to admit that I didn't do it myself though. Got frustrated with the darn thing and took it to a small engine shop near where I work. The man actually showed me how to do it. He rewound the coil spring onto the pulley from its outside edge to the inside, you start by pushing the outermost winding of the coil sping into the recess area it fits in on the pulley, and then work your way to the center. The trick is you have to rotate the pulley in your hands as you work towards the center. Once you get the spring all wound inside the recessed area, then it's a matter of aligning the pulley into the housing and dropping it in, making sure the inside (center) part of the coil spring catches on the little tab that locks that end of the coil in place.
Once that was done, he wound the housing around the pulley (CCW?) to preload the coil spring. I don't think he went as many turns as it would go, but rather backed off one or two turns, and then locked it in place by sticking a small philips screwdriver through the pulley and into the housing. You should also have the hole in the pulley for the rope lined up with the hole in the housing. This is so you can cut the old rope off, and then slide the new one in. Measure how much new rope you need by comparing it to the old rope. Slide the end through the housing and through the pulley. Tie a knot in the rope inside the pulley, and install the handle on the other end by sliding it on and tying a knot in it.
Once all that is done, pull the screwdriver out and gently let the coil spring retract itself, pulling in the new rope at the same time.
I also learned that you really don't need to remove the pulley anyway to do this, for this B&S motor anyway. In short, it's a matter of unwinding the pulley and lining things up, lock it in place, cutting off the old rope, sliding in the new rope, and then tying off both ends and releasing the lock so it will wind in the new rope.
I wish I could have videotaped it!! The best part was he only charged me $5 to do it, well worth it!! :laughing: