A broken pull cord can quickly turn your Troy-Bilt lawn mower from a reliable yard tool into a frustrating paperweight.
When the rope frays, the recoil mechanism jams, or a replacement part doesn’t fit right, you face delays and the hassle of repeated fixes.
Getting the correct pull cord replacement is essential for restoring quick, dependable starts without constant maintenance.
We focused on solutions that match OEM specifications such as 591139 and 497680, ensuring seamless compatibility across popular Troy-Bilt models.
Our research included evaluating hundreds of customer reviews, testing feedback, and price-to-performance ratios across top-performing parts.
Whether you need a full replacement assembly or just a durable rope kit, these options combine reliability and value.
1. YAMAKATO 4mm Pull Rope Handle – Best Budget Friendly
For the hands-on DIYer, the YAMAKATO 4mm Pull Rope Handle is an exceptionally economical and versatile solution.
Its primary strength lies in providing a generous 16 feet of durable 4.0mm rope, which is enough for two or three separate repairs across various machines.
The compound rope features a double-layer construction with a robust inner core and a tough outer sheath, specifically designed for enhanced strength and abrasion resistance, solving the common problem of premature cord fraying.
The specially contoured handle also offers a comfortable and secure grip, which is a noticeable upgrade over many stock handles.
While the rope is universally applicable to machines from Honda, Predator, and Briggs & Stratton, success depends on correctly tensioning the spring during reassembly.
This is not a plug-and-play fix but a kit for a more involved repair, ideal for homeowners on a tight budget who are comfortable with the re-spooling process.
Key Features:
- Provides 16 feet of durable 4.0mm rope.
- Durable cord features a double-layer construction.
- Includes a comfortable and secure specially contoured handle.
- Universal fit for many small engines (Honda, B&S, Generac, etc.).
Pros:
- Extremely affordable.
- Long 16ft rope ensures multiple repairs.
- Enhanced strength and abrasion resistance.
- Universal fit for various brands.
Cons:
- Requires manual labor for re-spooling.
- Does not include housing or spring.
- Demands mechanical skill and patience.
2. ZeeKee 591139 Recoil Pull Starter – Best Value for Money
Striking an ideal balance between quality and affordability, the ZeeKee 591139 recoil assembly presents a fantastic value proposition.
It is engineered as a direct-fit replacement for popular push mowers, including the Troy Bilt TB110 and TB200 models.
The unit’s construction features an ultra-durable Manila fiber drawstring and a sturdy PVC handle, chosen to solve the core problem of weak OEM cords that snap unexpectedly.
The starter’s 172mm mount hole distance aligns perfectly with specified Briggs & Stratton 140cc and 150cc engines, eliminating guesswork during installation. The pull action is consistently smooth with low noise, providing a clean start.
This is a straightforward unbolt-and-replace job that restores functionality quickly. It is the go-to choice for the majority of residential push mowers needing a quick and effective recoil starter replacement, tailored for the common 140cc/150cc engine family.
Key Features:
- Direct-fit replacement for Troy Bilt TB110 and TB200.
- Replaces BS 591139, 593961, 590588, 593959.
- Constructed with Manila fiber cord and a sturdy PVC handle.
- Engineered for 140CC and 150CC Briggs & Stratton engines.
Pros:
- Excellent value.
- Direct OEM fit.
- Durable materials used for longevity.
- Quick installation process.
Cons:
- Specific engine fit required.
- Features are relatively basic.
3. SOFO 497680 Rewind Starter Assembly – Best for 6.75HP Engines
The SOFO 497680 is the definitive solution for mowers with higher-displacement motors, powerfully built for bigger engines.
This assembly is specifically designed for the robust Briggs & Stratton 6.75HP and 190cc engines commonly found in models like the Troy Bilt TB210 and TB230.
A key advantage is the inclusion of four mounting bolts, a thoughtful detail that streamlines the repair process right out of the box. In terms of performance, this recoil starter is engineered to handle the higher compression of a 6.75HP engine.
The internal assembly provides a strong, positive engagement with every pull. The sturdy manila fiber cord and PVC handle contribute to a feeling of durability, ensuring it can withstand the force required for repeated starts on these more powerful machines. It is the correct, purpose-built choice for specific Briggs & Stratton powered Troy Bilt mowers.
Key Features:
- Designed specifically for 6.75HP and 190cc Briggs & Stratton motors.
- Compatible with Troy-Bilt TB210 and TB230.
- Made with durable Manila fiber cord and a PVC handle.
- Package includes the recoil starter, pull rope, and four mounting bolts.
Pros:
- Robust build handles high compression.
- Mounting bolts are included.
- OEM quality feel.
- Solid, reliable fix for specific engines.
Cons:
- Limited compatibility to 6.75HP engines.
- Not suitable for smaller engines.
4. GCV160 Honda Recoil Starter – Best for Honda Engines
This recoil starter is the definitive fix for mowers powered by Honda’s legendary engines. It is precision-engineered for perfect compatibility with the Honda GCV135 and GCV160 engine series, a power plant found on many high-quality Troy-Bilt mowers.
It replaces a host of OEM part numbers like 28400-ZL8-023ZA and provides a fit and finish that rivals the original factory part. In practice, the unit delivers the smooth, low-effort pull that Honda engines are known for.
The housing is made of a durable acrylonitrile-butadiene-styrene (ABS) plastic, which resists damage from fuel, oil, and impacts.
For anyone struggling with a faulty starter on their Honda-powered machine, this assembly is the key to restoring that satisfyingly quick and easy one-pull start. It is purpose-built for Honda’s unique mounting pattern and pawl engagement system.
Key Features:
- Perfect compatibility with Honda GCV135 and GCV160 engines.
- Replaces OEM part numbers like 28400-ZL8-023ZA.
- Housing constructed from durable Acrylonitrile-butadiene-styrene plastic.
- Engineered for smooth and fast starting operation.
Pros:
- Perfect Honda fit.
- Smooth and low-effort operation.
- Durable ABS plastic housing.
- Functions as a high-quality OEM alternative.
Cons:
- Compatible with Honda engines only.
- Completely incompatible with Briggs & Stratton engines.
5. AUTOKAY 591139 Pull Start Assembly – Best Lightweight Design
The AUTOKAY 591139 recoil starter presents a streamlined and effective solution that is a no-frills, direct replacement part.
It focuses on providing a lightweight yet functional fix for the most common Troy Bilt and Craftsman mowers equipped with 140cc or 150cc Briggs & Stratton engines.
As a direct replacement for the widely used OEM part 591139, it bolts on perfectly to compatible engines like the popular 550ex series, ensuring a hassle-free installation.
This assembly is designed to solve the single most common mower starting problem—a broken pull cord—without unnecessary complexity or cost.
The pull action is consistent, and the recoil mechanism engages reliably, immediately resolving the frustration of a limp or severed cord.
It performs its core function admirably, making it an excellent choice that prioritizes function and ease of installation above all else.
Key Features:
- Lightweight and functional design.
- Direct replacement for OEM part number 591139.
- Compatible with Troy Bilt TB110, TB200, and 140CC/150CC engines.
- Provides a simple and effective solution for a broken cord.
Pros:
- Lightweight design.
- Direct replacement ensures perfect fit.
- Simple installation process.
- Broad compatibility across B&S 591139 engines.
Cons:
- Basic materials used.
- Lacks additional features.
6. HONEYRAIN 591139 Recoil Starter – Best Durable Build
Engineered for longevity, the HONEYRAIN 591139 recoil starter is a decidedly robust replacement part built to withstand the rigors of frequent use.
It is a direct-fit solution for popular Troy Bilt models like the TB110 and TB200, designed to outlast less substantial alternatives. This assembly solves the problem of premature failure by using reinforced components where they matter most.
The heavy-duty plastic housing and strengthened internal components provide a reassuringly solid feel.
A key performance benefit is the crisp and strong recoil action, which ensures the cord retracts fully and neatly every time, addressing a common failure point on worn-out original starters.
It is an ideal choice for those who want a long-term fix with minimal downtime, providing a more substantial and lasting solution compared to a rope-only kit.
Key Features:
- Features heavy-duty plastic housing and strengthened internal components.
- Engine fit includes Briggs and Stratton 450E through 575E engines.
- Provides a crisp and strong recoil action.
- Replaces OEM part BS 591139.
Pros:
- Durable construction.
- Strong recoil spring ensures full retraction.
- Precise fit for compatible models.
- Easy to install as a complete unit.
Cons:
- May feel slightly heavier than basic models.
- Standard design visually.
7. Anxingo 497680 Starter with Filter – Best with Air Filter Bundle
The Anxingo 497680 kit is the complete tune-up package for owners of more powerful mowers. It provides a robust recoil starter for 6.75HP Troy Bilt models like the TB210 and TB230 and also includes a crucial maintenance item: a replacement 491588S air filter.
This smart bundling addresses both a common point of failure and a routine service need in one convenient purchase.
The recoil starter itself is built to handle the higher demands of 190cc engines, delivering a smooth and dependable pull start after a quick installation.
The ability to bundle the repair with preventative maintenance allows users to swap in the new air filter while replacing the starter, which can noticeably improve engine breathing and overall performance, turning a simple repair into a valuable tune-up. This kit provides superior value by bundling two common replacement parts.
Key Features:
- Includes a recoil starter assembly and an air filter.
- Compatible with 6.75HP engines (TB210, TB230).
- Replaces part numbers 497680 and 498144.
- The bundled air filter (491588S) improves engine performance.
Pros:
- Includes a critical air filter for tune-up.
- Excellent value bundle.
- Two-in-one repair and maintenance service.
- Wide compatibility across brands (Toro, Lawnboy, MTD, Troy-Bilt).
Cons:
- Specific engine fit.
- Mounting bolts are not included.
8. Yinlowa 591139 Recoil Starter Assembly – Best Overall
The Yinlowa 591139 Recoil Starter Assembly is highlighted as a durable and reliable choice for a comprehensive replacement.
It offers high compatibility, fitting many popular Briggs & Stratton engines in the 450E-625EX series, as well as various Troy-Bilt models.
This assembly is designed as a direct replacement for multiple key part numbers, including BS 591139, 593961, 590588, and 593959.
The design prioritizes durable materials and easy installation, addressing the common frustration of complex repairs.
This complete starter assembly includes the housing, spring, pulley, and handle, ensuring everything works smoothly.
User feedback regarding this type of assembly often prioritizes ease of installation, particularly concerning spring tension and included hardware.
Choosing a complete assembly like Yinlowa is recommended if the entire recoil mechanism is damaged or worn for optimal performance and longevity.
Key Features:
- Complete starter assembly (housing, spring, pulley, handle).
- Compatible with B&S 450E-625EX engines and many Troy-Bilt models.
- Replaces multiple OEM part numbers, including 591139.
- Designed for durable use and easy installation.
Pros:
- Durable construction.
- Easy Installation.
- Compatible with a wide range of models.
- Ensures the entire mechanism works smoothly.
Cons:
- Higher price point compared to rope-only kits.
- Requires confirming engine specifics for proper fitment.
How to Choose the Right Pull Cord Replacement for Your Troy-Bilt Lawn Mower?
Replacing a worn or broken pull cord on your Troy-Bilt lawn mower can save you time and money compared to professional repairs. However, selecting the correct replacement part is crucial for a proper fit and reliable performance.
Match Your Engine Model and Part Number
The most important step is ensuring compatibility. Troy-Bilt mowers frequently utilize Briggs & Stratton engines, so replacements are typically labeled with Briggs part numbers such as 591139, 497680, or 593959.
You should check your mower’s manual or the existing recoil housing for the exact model and part number.
For instance, models like the TB110, TB210, or TB230 require specific assemblies. Common part numbers include 591139 (for smaller engines like 140cc/150cc) and 497680 (for larger 6.75HP engines).
Choose Between Full Assembly or Rope-Only Replacement
The decision depends on the extent of the damage:
- Complete Starter Assembly: If the entire recoil mechanism is damaged (including the spring or pulley), opt for a complete starter assembly (such as the SOFO or Yinlowa models). These kits include the housing, spring, pulley, and handle, ensuring everything functions smoothly and offering superior longevity.
- Replacement Pull Rope: If only the cord is broken, replacing just the pull rope (like the YAMAKATO 4mm rope) is a budget-friendly option. Ensure the rope is the correct diameter (usually 4mm or 5/32″) and length (at least 6 ft) for easy rewinding.
Look for Durable Materials
A quality replacement should be built to last. Look for assemblies that use manila fiber cords and reinforced plastic housings (like SOFO or GCV160 Honda models) to resist wear and UV damage.
Additionally, PVC or ergonomic handles offer a better grip, which helps reduce hand strain during pull-starts.
Check for Included Hardware and Warranty
Some kits offer additional value by including mounting bolts (like the SOFO kit) and even air filters (like the Anxingo kit).
Others, such as the AUTOKAY, may only include the assembly. For peace of mind, prioritize products with at least a 3-month warranty and responsive customer support.
Other beneficial features include low-noise operation, smooth rewind action, and pre-tested performance to avoid startup issues.