When the pull cord on your lawn mower breaks, the repair involves accessing the starter assembly to wind a new one. Learning how to replace the pull cord on a lawn mower is a straightforward DIY task that can save you time and money. This guide will walk you through the entire process with clear, step-by-step instructions.
You will need a few basic tools and a replacement cord. Most hardware stores carry universal pull cord kits, or you can get one specific to your mower’s model. With a bit of patience, you’ll have your mower starting smoothly again in no time.
How To Replace The Pull Cord On A Lawn Mower
This section covers the complete replacement procedure. Safety is paramount, so always disconnect the spark plug wire before beginning any work on your mower. This prevents the engine from accidentally starting while your hands are near the blade or recoil starter.
Tools And Materials You Will Need
Gathering the right items before you start makes the job much smoother. Here is what you’ll need:
- A replacement pull cord (check your mower’s manual for length and thickness)
- A set of screwdrivers (flathead and Phillips)
- A socket set or wrenches
- Needle-nose pliers
- A pair of scissors or a sharp knife
- A lighter or matches (for melting the rope end)
- A clean workspace
Step-By-Step Replacement Guide
Follow these steps carefully to install your new pull cord. The process is similar for most walk-behind rotary mowers, though some starter housing designs may vary slightly.
Step 1: Remove The Starter Assembly
First, ensure the spark plug wire is disconnected. Then, locate the starter housing on the top of the engine. It’s the plastic cover with the pull handle. You will typically need to remove three or four screws holding it to the engine. Keep these screws in a safe place. Some models may have the housing attached as part of a larger shroud; you might need to remove a few additional screws to free it.
Step 2: Access The Recoil Spring Mechanism
Once the starter assembly is off, turn it over. You will see the pulley and the old, broken cord. Carefully note how the remaining cord is routed through the housing and tied to the pulley. Before proceeding, it’s a good idea to place the assembly in a large, clear plastic bag. This is a safety tip to contain the recoil spring if it unexpectedly pops out, which can be dangerous and difficult to reassemble.
Step 3: Remove The Old Pull Cord
You need to release the tension in the recoil spring. Hold the pulley firmly with one hand. With your other hand, slowly and carefully pull the remaining cord out until the spring is fully unwound. The pulley should now spin freely. Untie the knot holding the cord to the pulley and remove the old cord completely. Also, remove the old handle if it’s still attached by untying or cutting the knot.
Step 4: Prepare And Install The New Cord
Cut your new pull cord to the same length as the old one, or as specified in your kit. Use the lighter to melt the cut ends slightly. This prevents the rope from fraying. Thread one end of the new cord through the hole in the pulley. Tie a secure knot, such as a double overhand knot or a figure-eight knot. Pull on it firmly to ensure it’s secure.
Step 5: Wind The Spring And Rope
This is the most critical step. Turn the pulley in the direction opposite of the cord pull (usually clockwise) until you feel resistance. This winds the recoil spring. Now, turn it an additional 2-3 full turns to create proper tension. While holding the pulley to prevent it from spinning back, carefully route the free end of the cord through the exit guide on the starter housing. You may need to use needle-nose pliers to pull it through.
Step 6: Attach The Handle And Reassemble
Thread the free end of the cord through the hole in the pull handle. Tie another secure knot, trim any excess, and melt the end. Gently release the pulley, allowing the cord to retract into the housing. Test the pull action a few times; it should retract smoothly. Finally, reattach the starter assembly to the engine with the screws you removed earlier. Reconnect the spark plug wire.
Common Issues And Troubleshooting Tips
Sometimes, things don’t go perfectly on the first try. Here are solutions to common problems:
- Cord Doesn’t Retract: The recoil spring may not be wound with enough tension. You’ll need to open the assembly again and add 1-2 more turns before re-routing the cord.
- Cord Retracts Too Forcefully: The spring may be over-wound. Let out a turn or two of tension.
- Spring Came Unhooked: If the spring pops out of its anchor, reassembly is tricky. You must carefully rehook it and slowly wind it back into place, which requires patience.
- New Cord Breaks Immediately: The cord might be too thin for your mower, or the knot could be catching on internal components. Ensure you’re using the correct spec cord and that the knot sits flush.
Preventative Maintenance For Your Pull Cord
To avoid future breaks, a little maintenance goes a long way. Regularly clean around the starter housing to prevent grass and debris from getting inside. When starting the mower, pull the cord straight out with a smooth, steady motion; avoid yanking it at an angle or pulling it all the way to the end with excessive force. Every few months, you can apply a small amount of silicone spray to the cord where it exits the housing to reduce friction.
Frequently Asked Questions
How Much Does It Cost To Replace A Lawn Mower Pull Cord?
A universal replacement pull cord kit typically costs between $8 and $15. Brand-specific kits might be slightly more. If you take it to a small engine repair shop, labor could add $40 to $60 to the total.
Can You Repair A Broken Pull Cord Without Replacing It?
If the break is near the handle, you can sometimes re-tie it. However, if the cord is frayed or broken inside the housing, a full replacement is the safest and most reliable fix. A spliced cord is weaker and likely to break again soon.
What Size Pull Cord Do I Need For My Lawn Mower?
The size is determined by thickness (diameter) and length. Common diameters are 3/32″ or 1/8″. Length can vary from 36 to 48 inches. The best way to know is to check your owner’s manual or measure the old cord before you remove it. Bring the old cord to the hardware store for a perfect match.
Why Does My Pull Cord Keep Breaking?
Frequent breaks can be caused by a frayed or damaged exit hole on the starter housing, a misaligned pulley, an overwound or damaged recoil spring, or simply using the wrong type of cord. Inspect the housing for sharp edges that might be cutting the cord.
Is It Difficult To Replace A Recoil Starter Spring?
Replacing just the spring is a more advanced repair than replacing the cord. The spring is under high tension and can be difficult to handle. For most people, if the spring is broken, it’s often more cost-effective to replace the entire starter assembly as a single unit, which is still a simple bolt-on job.