PW Sticking Pull Cord and Pressure Release

Ex-cell XC2800
2,800 PSI, 2.6 GMM
Honda GC190 Engine

First the issue… the pull cord is binding from compression I believe. The unit is around 4 years old and the problem started last year and I thought it was hydraulic lock as I was able to free it up by removing the plug, pull a few times and it was good to go. Started to happen more and more and now I can’t get it to pull through at all. I’ve been researching allot and tried just about everything and my question is can the pressure release mechanism be sticking and allowing pressure to build. I can’t think of anything else as I’ve tried:

Checked pump to eliminate; pulled cord with no pressure or with gun open, unloader valve at lowest setting… nope.
Checked pull cord for binding issues… nope.
Pulled spark plug; cord pulled freely, no oil or gas in cylinder, pulled 20 times to clear… nope.
Removed plug wire; still binding… nope.
Checked flywheel key… nope.
Checked EX/IN valve clearance; EX prefect .20, IN off very little, adjusted to .15… nope.

The only thing I can come up with is the pressure release on the Cam Pulley. It operates but when I pull it to the upper position is sticks in place. Does anyone think this can be the issue or is there anything else it could be.

 

If the compression release weight sticks, that could definitely be the problem.

 

That's about all I can come up with and at a loss for anything else it could be. Think I'm going to order a pulley and see what happens... thanks.

 

Try removing the spray tip and try starting it while holding the trigger open so as to relieve some pressure, I had problems starting mine this year and the tip was mostly clogged and wouldn't let the pressure out. Have a good one. Geo

 

Tried everything on the waterpump side except removing it so I figure it has to be a motor issue. Strange as to how it progressed with the pressure buildup over time. I was hoping to see if anyone else had the same issue and tried most everything I did. Only thing I can see that could possible cause it is the pressure relief mechanism. Going to see if a Honda small engine tech has a clue.

 

For anyone with a similar issue try setting both valves to .004. Pulled easy and started right up. I think that means the pressure release is sticking so I'll replace the pulley and hope all is good. Thanks for the replies...

 

.004 is what they should be set at. I just realized you had them waaay too loose in the original post.