How to Disassemble Troy Bilt Tiller

Disassemble the Electrical Wiring

• 1

  Pull off the black rubber spark-plug-cover wire, located on the top of the engine. Unscrew the spark plug with a spark plug socket and socket driver.

• 2

  Press in on the edges of the safety wire assembly and pull the connector apart. The safety wire assembly has a green wire on one side and a yellow wire on the other side.

• 3

  Disconnect the green ground wire from the engine block using an adjustable wrench. Electric-start tillers also have a red ground wire; disconnect the red wire if present.

• 4

  Remove the harness connection from the safety-switch assembly with an adjustable wrench. The harness connection is found on the right side of the battery.

PTO Lever and Throttle

• 5

  Cut through the plastic ties holding the throttle cable in place. Set the throttle to "Stop."

• 6

  Loosen the flanged lock nut beneath the clutch with an adjustable wrench. Remove the flat, pan-head screw located on the clutch assembly on the opposite side of the flanged lock nut with a screwdriver. Push the throttle into the "Start" position and remove the curved-head screw next to the pan-head screw.

• 7

  Remove the spring from the clutch using a set of needle-nose pliers to pull it free from the top flat PTO lever located directly underneath the handle. Grasp the spring near the hole and pull it out to the side and slightly toward the handle, then slowly release the tension and remove the spring from the bottom hole.

• 8

  Unscrew the nuts on the bolts attaching the PTO lever to the tines. Catch the star washers and the bushing that will drop out as you remove the bolts.

Disassemble the Handle

• 9

  Rotate the height-adjustment lever counterclockwise until it comes free. Catch the nut on the left side of the handlebars as you rotate the height-adjustment lever.

• 10

  Pull the height-adjustment lever out of the handle, removing one piece at a time. Label the side that the clamp and ratchet came from by putting a small piece of masking tape on the part and marking it L for left or R for right. From left to right you will remove the left clamp, left handlebar and left ratchet from the base. Continue to pull the height-adjustment lever out after you have labeled the left-side parts, removing similar parts from the right-hand side. In all, you will remove seven parts.

• 11

  Remove the screw attaching the wire harness to the base using a screwdriver. Unscrew the bolt in the base with an adjustable wrench.