I was going to order some Stens 146-027 #4 recoil rope, but decided that the rope I have should be good enough for several more years of use. I left it at the 37-1/4" length. I had a hell of a time getting the recoil pulley back onto the arbor. I cleaned up the burrs with a needle file, and of course the recoil spring jumped out. I was able to get it all back together and tested again before installing the recoil back on the engine. The pulley was grabbing and binding unevenly until I lubricated the shaft, then all was good. I took this opportunity to replace the five 6-32 machine screws which secure the recoil to the engine with some new stainless steel wire lockable 6-32 machine screws. Previously everytime I ran the engine the recoil screws would loosen up, so this should stop that from happening. I have to say this was by far the most painstaking recoil repair I have ever had to perform. I own over 300 air cooled engines, albeit most do not have recoils, but I can rebuild Briggs, Tecumseh, F-M, Kohler or Schnacke recoils in just a few minutes. This O&R was about seven hours of work start to finish. At least when it was all done, the engine started up and ran good. I am pretty happy with it. I will have to order or make a new diaphragm for the carburetor at some point. Spraying it with oil to make it plyable is only a temporary fix. As per the output shaft on the C-SAW, it uses a 1-1/16" o.d. steel pulley similar to the picture you posted in post #7. Thanks again for all of your help. Next time around, things should go much quicker.
Chris