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I have a Troy bilt tb6040 pull cord broke, took off and put new cord on can not get the spring held and put on over shaft!! Any hints??

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Posted on Jan 02, 2017

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SOURCE: TROY-BILT TB70SS - The pull cord broke and I need

Hello:

>>The Following is a General Instruction File I Made to Perform this Repair. If you have Any Suggestions or Remarks, then Please Let me Know. Thanks.
>>**Remove the Boom/Shaft from the Engine. Remove the Mounting Bolts and the Boom and Center Drive Shaft should Slide Away from the Starter Housing Assembly.
>>**On Some Model Trimmers, there is a Torx Screw Inside the Coupling Drive that has to be Removed.
>>****There is also a Locking Screw on the Side of the Housing that is a Anti-Vibration Lock.****
>>Using the Breakdown as a Guide Remove the Starter Housing Assembly from the Engine Assembly.
>>Now Carefully/Slowly Remove the Pressure Plate Assembly from the Starter Housing.
>>The Spring May have Broken and Sometimes a Section will Jump Out when the Pressure Plate Assembly is Removed from the Starter Housing. When it Jumps, it Pushes the Recoil Pulley Out Also.
>>Look at the Direction of the Coil of the Spring in the Housing and Make an Arrow in the Direction of the Coil with a Magic Marker on the Inside of the Housing.
>>Remove the Broken Spring and Clean the Housing with Spray Lubrication. You can Use Solvent if Required, Just be Sure to Wipe it Before Assembly with Spray Lubricant. The New Spring should come with a Retainer that Holds it in a Circle.
>>If you have Removed the Spring from the Retainer, then Use a Piece of Plastic Pipe About 2" Long that is the Same Inside Diameter as the Retainer (Slightly Smaller than the Recess that the Spring Coils Into if you Lost the Retainer).
>>Coil the Spring Into the Pipe and then Set the Spring Into the Recess. Make Sure the Spring Tab of the Spring Engages the Spring Lock in the Recess.
>>Use a Socket to Hold the Spring in Place and Pull the Pipe Out of the Recess.
>>Lock the Pulley in Place.
>>Now Turn the Pulley in the Same Direction that the Pulley would Turn if the Rope was Turning it.
>>Once the Pulley will Turn No More, then Reverse Direction 1 or 2 Turns and Thread the New Rope Through the Hole in the Center of the Pulley and Out the Hole in the Blower Housing.
>>Pull the Rope Through Until it is Tight Against the Pulley. Now Tie a Slip Knot in the Rope to Hold the Pulley in Place While the Handle is Attached to the Rope.
>>Once the Handle is Attached, Release the Slip Knot and the Rope Should Retract Into the Housing. Reassemble the Blower Housing Onto the Engine.
>>On Some Models you May have to Install the Rope Before you Lock the Pulley in Place. If So, there is a U in the Pulley that the Rope is Held in While Turning the Pulley to Tighten the Spring.
>>Go to this Site Addy, http://www.jackssmallengines.net/parts.asp and Select Shop Online Parts Look Up. Then Select the Model Tab and Enter the OEM (Troy Bilt)and the Model Numbers. Now Double Click on your Model in the Results Area.
Please, Do Not Hesitate, If you Hit a Snag or this Does Not Correct the Problem, I am Here if You Require More Assistance.
Hope this Helps. Let me Know What Happens, Please. May the All Mighty Bless You and Yours. Be Safe and Be Happy. Thanks.

Good Luck

Respectfully

jbridger (John)

Posted on May 11, 2009

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SOURCE: replacing pull cord on 4 cycle gas trimmer, troy bilt

these usually are threaded counter clockwise need a pair of channel locks to hold the flywheel then with the other hand crack nut open

Posted on Jun 30, 2009

  • 1 Answer

SOURCE: I have a Troy Bilt TBP6040 XP 4 cycle weed eater

I just had this same issue. I found out that you have to take the cord out of the handle then put the spool in. You then rotate the spool back in and align the spool with the spring and fish out the cord which will put a small amout of tension on it. You keep the tension on it and put the handle back on.

Rgds,
Mark J

Posted on Jul 23, 2009

rycgl
  • 1545 Answers

SOURCE: replace pull cord on troy-bilt tb70ss

Remove the tube that holds the flex-drive shaft from the front of the motor cover. Remove the throttle cable from the carburetor. Mark and unplug any wires for the on/off switch if possible. Now if you have pulled the driveshaft tube out of the way, the clutch drum is up next. Inside it, screwed into the very end of the engine's crankshaft is a Torx #25 screw. Before you loosen it, ou will have to lock up the engine. Remove the spark plug. Pull on the starter until the piston is down, then insert a length of clean, soft rope into the engine. The engine will come up and compress the rope, thus locking it in place to allow clutch drum and clutch removal. Loosen the T-25 screw inside the drum.. It probably won't come completely out...it is made this way. Next, remove the clutch. It is screwed onto a small threaded section of the crankshaft Removal is counterclockwise.. It will be pretty tight. To help, apply peneterating oil. Whack the ears of the clutch near the center with a dull flat-blade chisel and hammer unless there are bolts. then use wrench. It will turn counterclockwise for removal and there will probably be a removal direction arrow on it's face. After getting that off, remove the Torx screws holding the cover to the engine. The starter unit should be mounted inside as it mates with the bottom of the flywheel to start the motor. Remember to preload tension (5-7 turns) on the starter unit. Make sure the handle is installed. Jam the unit with a screwdriver or something so you can insert and tie off the new rope. Then remove jam device and let recoil pull your new rope into place. Reassemble and you are done. Disassembly requires Torx head drivers ranging from T-15 to T-25

Posted on Oct 03, 2010

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1 Answer

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Now the fun part. The wheel is spring loaded and the spring has no tension on it after the rope broke. Wind it up like a clock spring until it is tight then back off until the holes where the cord goes line up. Stick a small screw driver, nail, ect in the slot to keep it from unwinding . Do not tie the handle to the cord yet. Slide the new cord through the hole in the cover and wheel and then tie a knot in the cord and pull it snug in the wheel. Hold the rope and remove the pin and let the cord slowly wind itself up. Run the cord through the hole in the handle, Adjust to the length of pull you want and tie another knot.
Reinstall the motor cover (if it binds and wont go on, pull the rope just a little bit to line up the crank with starter wheel and it will slide down.)

It sounds a bit windy but it really is a simple fix.

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1 Answer

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Rgds,
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