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Need to replace pull rope - Troy Garden

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  • 2strokeguy
    2strokeguy Aug 24, 2010

    What are we working on?

  • rickw1953 Aug 24, 2010

    I have a Troybilt TB90BC trimmer/ brushcutter the pull rope broke . It looks like the clutch assembly needs to be removed so I can get to the flywheel but I can't tell how to remove it !

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You will need to lock down the cylinder to remove the clutch. This is not an easy repair. Remove the spark plug and lower the piston. Take a piece of small rope (the broken one works fine) and fill the cylinder with the rope. Raise the piston to "lock the cylinder. The clutch drum can now be removed by inserting a T15 or T20 torx into the center and turn the screw counter-clockwise. Then take a pair of large slip-joint pliers and turn the clutch assembly counter-clockwise to remove. Make note of what order all the little washers come off. Also, make sure to remove the clutch as an assembly...it is very difficult to put back together. When reinstalling the clutch, it is VERY important to get it tight. Failure to get the clutch tight will result in major engine damage.
Make sure you replace the rope with 40" of #3.5 braided rope. Melt the ends of the rope so it doesn't fray and use a figure 8 knot to secure.
Good luck!

Posted on Aug 27, 2010

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How do I replace the pull cord on snapper sr1330 riding mower


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1 Answer

The pull cord broke I just can figure out how to


1) Remove the recoil housing
**NOTE: normally you DO NOT need to remove the rotor pulley or spring to replace the rope.
This is the area that causes so many guys a lot of extra trouble!
2) Locate the string that is left and the hole it is threaded thru
3) Determine how much string has broken off of the rope that came out
*Note: if more than 1 inch is left, then the rope needs to be replaced
4) Obtained a length of rope appropriate for your engine, it is always better to have too much rope.
You can always shorten if it is too long.
Make sure both ends are melted to a point for easier threading thru handle and rope rotor
5) Wind the rotor in the direction of what the rope would pull,
(this will tighten the spring) until the spring is completely wound.
Remove 1/2 to 1 revolution.
6) Install the rope (with the handle installed on one end) thru the recoil housing and towards the rope rotor.
Tie a knot in the end of the rope, leaving a 3/8" tail free.
Then allow rope to wind onto the rotor until all rope is wound.
8) Pull the rope several times to position rope properly into rotor.
*note : there should be NO droop in the handle after released
9) When the unit is functioning proplerly, re-install housing onto engine.

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Take the housing off for the pull rope. Inside you'll find a spool. Take that off and underneath you'll find a spring. Replace the pull rope and connect it to the spool like the old one is. With the handle outside of the case run the rope through the pull rope hole then attach it to the spool. Wind all but a foot or so of the new rope back onto the spool. The spring will have a way of attaching to the case and to the spool. Attach the springs to the case. There will be a notch cut into one side of the spool. You need to lay the rope into this notch and then place spool back into the case at the same time attaching the spring to the spool. Don't worry about tensioning the springs. Once the spool is back in you need to start winding up the spool in the direction that tightens the spring. You'll need to make about 5-8 rotations depending on the length of the rope. At this point, position the notch in the spool even with the hole where the pull rope enters the case. Pull on the pull rope handle until you pull the slack rope back through the notch and outside the housing. Then release the rope and the slack should be pulled back inside the housing and wrapped around the spool. Here is a video on changing a pull rope on a lawn mower. The idea is basically the same.

http://www.youtube.com/watch?v=i3ZMVFi0yqY

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Before installing fasteners for the recoil to the housing, pull the rope a small amount 2-4". With a small pressure from your other hand, at the same time push gently down on the recoil housing. This should partially rotate the flywheel and align the pawls to the rope rotor. Repeat this proceedure until you feel the pawls drop into place.
You may want to review the proceedure for installing a rope to complete your repair.

1) remove the recoil housing
**NOTE: normally you DO NOT need to remove the rotor pulley or spring to replace the rope. This is the area that causes so many guys a lot of extra trouble

2) locate the string that is left and the hole it is threaded thru

3) determine how much string has broken off of the rope that came out

Note: if more than 1 inch is left, then the rope needs to be replaced

4) after rope is obtained, make sure both ends are melted to a point for easier threading thru handle and rope rotor

5) install the rope (with the handle installed on one end) thru the recoil housing and towards the rope rotor.

6) with the rotor free of tension, route the rope from the groove toward center and up thru the hole. Tie a knot in the end of the rope, leaving a 3/8" tail free.

7) wind the rotor in the direction of what the rope would pull (this will tighten the spring) until the spring is completely wound. remove 1/2 to 1 revolution, and then allow rope to wind onto the rotor until all rope is wound.

8) Pull the rope several times to position rope properly into rotor.
*note : there should be NO droop in the handle after released
If droop is evident, wind the rotor and rope 1 revolution tighter so there is no droop of handle when released

9) when unit is functioning proplerly, re-install housing onto unit

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First, remove the recoil assembly but dont disassemble!
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