How to Repair the Starting Cord on a Troy-Bilt Gas Trimmer
The starting cord on a Troy-Bilt gas trimmer is responsible for starting a cold engine. This cord wraps around the pulley, which in turn is attached to the flywheel. When the flywheel gets spinning fast enough, it causes the ignition coil to discharge the spark. The starting cord, therefore, needs to pull out and recoil quickly back onto the pulley. If anything, like a sticky cord or broken recoil spring, is stopping this mechanism, your engine won't start. Does this Spark an idea?
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Instructions
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Unscrew the four mounting screws holding the starting cord and the starter cover to the back of the Troy-Bilt's engine. Remove the mounting screws and pop off the cover using the flat blade of the screwdriver as a wedge. Lift off the cover and turn it upside down to work on the starting cord.
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Pull out about 10 inches of the starting cord. Wind the 10 inches into a loop. Grab the fold of the loop and push it into the notch on the pulley. Wiggle the loop back and forth while holding the cover. Wiggle the cord until the recoil spring lets go of the pulley. Let out the tension on the spring slowly with your hand.
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Pull the starting cord completely out of the pulley. Check the cord for tears, frays or any sticky substance, like dirt or oil, that may be causing the cord to stick to the pulley. Cut the cord off the pulley and handle if it needs to be replaced.
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Unscrew the pulley and remove from the cover by taking off the screw on the metal starter post. Take the pulley off the cover and turn it over. Wedge the flat tip of the screwdriver underneath the recoil spring cassette. Pop the spring out of the center slowly, while placing your hand over it to prevent it from accidentally hitting you.
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Clean the pulley and the recoil spring cassette with the rag and mild dish detergent. Check them for cracks, warping and other signs of damage. Replace bent or broken springs; replace any pulley that shows signs of damage.
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Lubricate the metal post with your fingers, spreading enough on to coat the post in a thin layer. Slide the recoil spring cassette back into the pulley's center. Turn the pulley over and put it onto the post. Tighten the starter post's screw. Thread the cord, if you took it off or replaced it, through the pulley. Tie a knot in both ends of the cord to anchor it to the pulley and the starter handle.
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Wrap the cord around the pulley in a clockwise direction. Withdraw another 10 inches of cord. Put a loop into the 10 inches and put the fold into the pulley's notch. Wiggle the loop until the recoil spring catches onto the pulley.
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Wind the pulley clockwise 5 to 7 times to reset the tension on the recoil spring. Take your hand off the loop and let the cord recoil onto the pulley. Turn the starter cover over and tighten down the four retaining screws. Check the function of the starting cord; if it still doesn't work properly replace the cord, pulley and recoil spring.
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Tips & Warnings
The spring is under a lot of tension, so wear safety glasses when operating on the starter mechanism.
