How to Replace the Recoil Spring on a Troy-Bilt Trimmer

The rewind spring pulls the starter rope back into the starter when starting the engine. After years of use, the rewind spring will wear and eventually break. The spring will typically break at one of its ends, where it attaches to the pulley or the housing. This wear can be accelerated when using excessive force when pulling the starter rope or if the rope is routinely pulled out to its full length when starting the engine. If the recoil spring breaks, it won't retract the rope back into the starter.

Let's get started.

REMOVING THE RECOIL SPRING   1. Loosen the trigger housing.

a. Remove the pivot screw from the trigger assembly.
b. Loosen the remaining screws securing the two halves of the trigger assembly.
2. Remove the clutch cover.

a. Remove the screws securing the clutch cover to the upper shaft assembly.
b. Separate the lower shaft assembly (including the trigger housing and lower drive shaft) from the engine assembly.
c. Remove the clutch cover from the engine housing.
3. Remove the clutch drum.

a. Loosen the screw securing the clutch drum (the screw will remain captive within the drum).
b. Remove the clutch drum from the clutch.
4. Bind the engine.

a. Remove the spark plug boot.
b. Use a spark plug wrench or socket to remove the spark plug.
c. Insert an old starter rope into the cylinder (through the opening for the spark plug). Continue feeding the starter rope into the cylinder until the piston is unable to cycle up and down.
5. Remove the clutch.

a. Use an adjustable wrench to loosen the clutch.
b. Unthread and remove the clutch from the crankshaft.
c. Remove the clutch washer.
6. Remove the rear engine cover.

a. Remove the screws securing the rear engine cover.
b. Remove the rear engine cover.
7. Remove the starter housing.

a. Remove the screws securing the starter housing to the engine.
b. Remove the starter housing assembly.
8. Remove the starter recoil spring.

a. Slide the starter handle away from the knotted end of the starter rope.
b. Untie (or cut, if necessary) the knot in the end of the starter rope.
c. Release the starter rope into the starter housing (to remove the tension from the starter spring). Obviously, this step will not be necessary if the recoil spring on your tool has failed completely.
d. Remove the screws securing the retaining plate.
e. Remove the retaining plate from the starter housing.
f. Use pliers to remove the retaining ring from the starter pulley (the ring will need to be replaced).
g. Remove the starter pulley from the housing.
h. Remove the starter rope from the pulley.
i. Remove the starter recoil spring from the housing.

INSTALLING THE NEW RECOIL SPRING

  9. Install the starter recoil spring.

a. Align the outer tab (on the new starter recoil spring) with the slot on the starter housing and install the recoil spring assembly into the starter housing.
b. Align the notch on the starter pulley with the tab on the center hub and install the starter pulley into the starter housing.
c. Install the new retaining ring to secure the starter pulley and recoil spring.
10. Tension the recoil spring.

a. Rotate the starter pulley clockwise (about 5 full turns) to tension the recoil spring.
b. Once the recoil spring is tensioned, you will need to maintain pressure on the spring assembly throughout the remaining steps. Do not allow the spring to recoil until the starter handle has been installed and secured to the starter rope.
c. Align the opening in the starter pulley with the eyelet on the starter housing.
d. Thread the starter rope through the eyelet (from outside to inside) in the starter housing and through the opening in the starter pulley.
e. Use pliers to pull the starter rope through the slot on the side of the starter pulley.
f. Tie a knot in the (pulley-side) end of the starter rope.
g. Pull the starter rope (from outside the starter housing) to seat the knotted end in the starter pulley.
h. Tie a temporary knot in the starter rope (outside the starter housing) to prevent the rope from recoiling beyond the eyelet in the housing.
i. Install the starter handle onto the starter rope.
j. Tie a knot in the end of the starter rope.
k. Tuck the knot into the slot on the top of the starter handle.
l. Remove the temporary knot from the starter rope.
m. Allow the starter rope to recoil into the starter housing.

REASSEMBLING THE UNIT

  11. Reinstall the pulley retaining plate.

a. Install the pulley retaining plate.
b. Secure the retaining plate with the screws.
12. Reinstall the starter housing.

a. Install the starter housing onto the engine assembly.
b. Secure the starter housing with the screws.
13. Reinstall the rear engine cover.

a. Install the rear engine cover.
b. Secure the rear engine cover with the screws.
14. Reinstall the clutch.

a. Install the large clutch washer.
b. Thread the clutch onto the spindle.
c. Use adjustable pliers to tighten (and secure) the clutch.
15. Unbind the engine.

a. Remove the rope from the cylinder.
b. Install the spark plug.
c. Install the spark plug boot.
16. Reinstall the clutch drum.

a. Install the two small clutch washers.
b. Install the clutch drum.
c. Secure the clutch drum with the (captive) screw.
17. Re-connect the lower shaft assembly to the engine.

a. Install the clutch housing over the clutch drum.
b. Connect the lower shaft assembly to the engine.
c. Align the anti-rotation (pivot) holes in the trigger housing with the shaft assembly.
d. Install and tighten the anti-rotation screws.
e. Secure the trigger housing with the remaining screws.
f. Secure the clutch housing with the remaining screws.