A little tip here in removing the nylon plunger if it really is stuck fast. Drill a small hole right in the centre about 5mm deep with a 1-1.5mm drill then use a wood or appropriately sized self tapping screw and just screw the tip in until it grabs the nylon follower, it will then start to turn the nylon insert at which time you can withdraw it from the metal part. If you only have a slight level of interference then its easy to create a better fit by hand sanding using some fine 240 wet and dry paper with WD40 or similar however if you have considerable swelling you can open the central drill hole up to 5/6mm then mount it onto a bolt. I drilled mine at 5mm and tapped a six millimetre thread in it so if I need to revisit it again I can just use a 6mm machine screw to remove it either by screwing in and pulling or using the screw as a jack against the metal element. You can now mount it in a drill, preferably a pillar drill but not impossible in a hand drill, and as you have it rotating gently sand it until you have a free fit in the bolt. There is no reason why this hole will cause any problem and in fact it may well aid lubrication!
As an aside, Sthil power tools seem to have exactly the same issue with all there pull starts in that the retractable cord pully spindle jams shortly after
The first few uses and needs sanding down. It looks very much like the same material to me!
Last edited by sewin; 20/08/26 12:19 PM.
