Just went through this pain today. Here's how I did it. Use allen wrench with T handle to remove the shroud over the carb controls and plug. Then remove about 10 screws and split the case. Use tool that comes with the unit to remove the nut holding the impeller. Behind the impeller, use torx head to get the other bolts to remove the motor. There are two other screws on the other side that hold the motor on. Drop the motor from the case carefully. It is still attached by wires to the throttle and kill switch. Note how the throttle linkage is connected because it will come apart for sure. On the one side of the housing you are looking at the plastic cord spool with the spring unit behind it. My chord simply pulled out of the spool. It was held on with a 10mm nut and start washer (not a good design). If the chord broke, remove the remnant from the take up spool. To rewind the new chord or replace the one that pulled free, you need to wind the spring to put tension on it. Make sure the take up spool engages with the spring tang otherwise it will turn free and not tense the sprint. Once engaged with the tang, the spool should set to the bottom to be level with the metal chord guide. Turn the spool clockwise 3-4 turns until you feel it tighten. With a 2nd pair of hands, hold the tension on the spool and tread in your chord. Route the chord through the take up reel into the hole on the side. Loosen the 10mm nut with the star washer and route the end of the chord through it. Tie a simple knot in the end to prevent it from pulling through. Tighten the 10mm nut which clamps on the chord. Now, slowly, let the spring tension take up the loose chord until fully retracted. Make sure the metal chord guide fits in the slot to channel the chord properly into the take up reel. Hold the spool down and give the chord a gentle test or two. The chord should retract easily and fully. Simple as pie!!! Reverse the disassembly and you are back in business.
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