Learning how to replace pull cord on lawn mower is a straightforward repair that can save you time and money. Swapping out a broken pull cord on your lawn mower restores the manual starting mechanism to working order. You do not need to be a mechanic to handle this fix. With a few common tools and a replacement cord, you can have your mower starting smoothly again in under an hour.
This guide will walk you through the entire process step by step. We will cover safety first, the tools you need, and detailed instructions for accessing and replacing the cord. You will also learn how to wind the recoil spring properly, which is often the trickiest part. By the end, you’ll have the confidence to tackle this repair yourself.
How To Replace Pull Cord On Lawn Mower
The core process involves removing the starter assembly, installing a new cord, and carefully rewinding the spring. While the steps are similar for most walk-behind mowers, always consult your owner’s manual for model-specific details. The most critical step is handling the recoil spring with care, as it is under tension and can snap or unwind rapidly if released.
Before you begin, gather all necessary tools and parts. Working in a clean, well-lit area will make the job easier. Ensure the mower is on a flat surface and the engine is completely cool. Taking your time during this repair will lead to a successful outcome and prevent any injuries or further damage to the mower.
Tools And Materials You Will Need
Having the right items on hand before you start is essential. You likely already have most of the required tools in your basic toolkit. Here is a complete list of what you need to complete the pull cord replacement.
- Replacement pull cord (check your mower’s manual for correct length and diameter)
- Socket set and ratchet or a screwdriver (typically Phillips head)
- Needle-nose pliers
- Safety glasses and work gloves
- A pair of vise grips or a clamp
- Scissors or a sharp knife
- A small container for loose screws
- Light machine oil or grease (optional, for lubrication)
Safety Precautions Before Starting
Your safety is the most important part of any repair. A lawn mower contains several components that can cause injury if not handled correctly. Following these precautions will help ensure you complete the job without any accidents.
- Disconnect the spark plug wire. This is the most crucial step to prevent the engine from accidentally starting while you are working on it.
- Allow the engine to cool completely if the mower has been used recently to avoid burns.
- Wear safety glasses to protect your eyes from dirt, debris, and the recoil spring.
- Work gloves will protect your hands from sharp edges and pinching.
- Work in a clean, flat area where you have plenty of space to lay out parts.
Step-By-Step Replacement Guide
Now, let’s get into the detailed steps for replacing the pull cord. Follow each step in order, and take pictures with your phone if you need a reference for how parts were arranged before you removed them.
Step 1: Remove The Starter Assembly
First, you need to access the recoil starter mechanism. This is usually housed under a plastic cover on the top of the mower engine.
- Locate and disconnect the spark plug wire, securing it away from the plug.
- Using your socket set or screwdriver, remove the bolts or screws holding the starter cover in place. There are usually three or four.
- Carefully lift the cover straight off. Sometimes it is connected to the recoil assembly itself, so be prepared for the whole unit to come loose.
- Place the cover and any associated parts aside in a safe place.
Step 2: Release Tension And Remove The Old Cord
With the assembly exposed, you will see the pulley and the coiled spring. The goal now is to safely release the tension in the spring to remove the broken cord.
- If the cord is completely broken, you may need to use needle-nose pliers to pull the knot out of the pulley hole.
- Slowly allow the pulley to rotate in the direction it would if you were pulling the cord. Let it unwind until all tension is released from the spring. Do not let it snap back.
- Once the tension is gone, you can lift the pulley out of the housing. Note the orientation of the spring ends—one end hooks into the pulley, the other into the housing.
- Untie or cut the knot on the old cord and remove it from the pulley and handle.
Step 3: Prepare And Install The New Pull Cord
Now, you will thread the new cord through the handle and the pulley. It’s easier to attach the handle first before dealing with the spring tension.
- Thread one end of the new cord through the hole in the starter handle and tie a secure knot. Trim any excess cord.
- Feed the other end of the cord through the hole in the pulley. Pull it through until the handle is close to the pulley, then tie a preliminary knot that you can adjust later.
- Do not tighten this knot fully yet. You will need to wind the spring and then adjust the cord length so the handle rests properly when retracted.
Step 4: Wind The Recoil Spring And Reassemble
This is the most delicate part of the process. The recoil spring must be wound to provide the retracting force for the cord.
- Place the pulley back into the housing, ensuring the inner hook of the spring engages with the slot in the pulley.
- Using your fingers or a flat-head screwdriver, rotate the pulley in the direction opposite of the cord pull (usually clockwise). You will need to make about 4-6 full rotations to create enough tension.
- Hold the pulley in place with one hand. With your other hand, pull the cord slowly to draw it into the housing, winding it neatly onto the pulley.
- Once the cord is mostly wound and the handle is near the housing, tighten the knot on the pulley securely. Trim the excess cord.
- Allow the pulley to slowly turn back, feeding the cord into the housing until the handle rests snugly against the starter cover.
- Replace the starter assembly cover and secure it with the original bolts or screws. Reconnect the spark plug wire.
Testing Your Repair
After reassembly, it’s time to test your work. Do this carefully to ensure everything functions correctly and safely.
- Ensure the area around the mower is clear.
- Give the pull cord a slow, steady pull to feel for any binding or unusual resistance. It should pull out smoothly and retract fully.
- If the cord does not retract, the spring may not have enough tension. You will need to open it back up and add a few more winds.
- If the cord retracts too forcefully or gets stuck, there may be to much tension or the cord is binding. Check the alignment of the pulley and housing.
- Once the cord action is smooth, you can attempt to start the engine as you normally would.
Common Problems And Troubleshooting
Sometimes, things don’t go perfectly on the first try. Here are solutions to common issues you might encounter during or after the replacement.
Pull Cord Does Not Retract
If the cord stays out after you pull it, the recoil spring is likely not engaged or is broken. You will need to reopen the housing and check that the spring end is properly hooked into the pulley. If the spring is broken, you will need to replace the entire recoil assembly.
Pull Cord Is Too Hard To Pull
Excessive resistance can have a few causes. The spring may be overwound, creating to much tension. The cord itself could be fraying and catching inside the housing. Also, check that the pulley is sitting flat and not rubbing against the housing.
Pull Cord Retracts Too Fast Or Slaps The Housing
This usually indicates that the cord is not wound evenly on the spool or that the handle is not providing enough drag. Ensure the cord is wound neatly and that the handle moves freely on the cord. A small amount of lubrication on the spring can sometimes help smooth the action.
Preventive Maintenance Tips
Taking care of your pull cord can extend its life and prevent future breaks. Simple habits can make a big difference.
- Always pull the cord straight out. Angled pulls cause uneven wear on the cord and the pulley.
- Do not yank the cord violently. Use a smooth, steady motion to start the engine.
- Periodically clean around the starter assembly to prevent grass clippings and dirt from getting inside.
- Lightly lubricate the recoil spring and pulley post once a year with a dry lubricant or light oil.
- Inspect the cord for fraying at the handle or pulley hole each time you use the mower.
Frequently Asked Questions
Here are answers to some common questions about replacing a lawn mower pull cord.
How Much Does It Cost To Replace A Pull Cord On A Lawn Mower?
A replacement pull cord typically costs between $5 and $15. If you need to replace the entire recoil starter assembly, the cost can range from $20 to $50. Doing the repair yourself saves on labor costs, which can be $50 or more at a small engine shop.
Can I Use Any Rope As A Replacement Pull Cord?
It is not recommended. Lawn mower pull cord is specifically designed to be durable, flexible, and resistant to weather and abrasion. Using a generic rope like nylon or paracord may work temporarily, but it can fray quickly, lack the necessary grip, and may not handle the heat and friction inside the housing.
How Often Should A Pull Cord Be Replaced?
There is no set interval. A pull cord should last for several years with proper use. Replace it when you notice significant fraying, when it becomes difficult to pull, or when it breaks. Regular inspection is your best guide for when a replacement is needed.
What If The Recoil Spring Is Broken?
If the recoil spring is broken, you will need to replace the entire starter assembly. Repairing just the spring is extremely difficult and dangerous due to the high tension. Replacement assemblies are readily available and are often easier and safer to install than trying to fix the individual spring.
Is It Hard To Replace A Lawn Mower Pull Cord?
For most people, it is a moderately easy DIY repair. The hardest part is managing the recoil spring tension. If you follow instructions carefully, wear safety gear, and take your time, you can successfully complete the job. If you are uncomfortable, a small engine repair shop can do it quickly.