Learning how to replace pull cord on a lawn mower is a common DIY repair that can save you time and money. The process involves rewinding the spring inside the starter housing, which sounds more daunting than it is. With basic tools and a bit of patience, 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 everything from diagnosing the problem to safely handling the recoil spring. You’ll learn what tools you need and how to avoid common pitfalls.
By the end, you’ll feel confident tackling this repair yourself. Let’s get your mower back in working order.
How To Replace Pull Cord On A Lawn Mower
Before you begin, gather the necessary tools and parts. You will need a replacement pull cord, which you can buy at any hardware store or online. Make sure to get the correct length and thickness for your mower model.
You will also need a set of basic hand tools. A socket set, screwdrivers, and pliers are essential. Having a pair of work gloves is also a good idea to protect your hands.
Safety is paramount. Always disconnect the spark plug wire before starting any repair. This prevents the engine from accidentally starting while you are working on it.
Tools And Materials You Will Need
Having everything ready before you start will make the job go smoothly. Here is a complete list of what you should have on hand.
- Replacement pull cord (check your mower’s manual for specifications)
- Socket wrench set and screwdrivers (flathead and Phillips)
- Needle-nose pliers and regular pliers
- A pair of sturdy work gloves
- Safety glasses
- A clean, well-lit workspace
- Light machine oil or grease (for lubrication)
Step 1: Remove The Starter Assembly
The first step is to access the recoil starter. This is the housing that contains the spring and the cord. On most mowers, it is held on by three or four bolts.
Locate the bolts around the starter housing. Use your socket wrench to carefully remove them. Keep the bolts in a safe place, as you will need them later.
Once the bolts are out, gently lift the starter assembly away from the engine. Be cautious, as the spring inside is under tension. Set the assembly on your workbench with the pulley facing up.
Step 2: Release The Old Cord And Spring Tension
Now you need to safely release the energy stored in the recoil spring. This step requires careful attention to avoid injury.
First, note how the cord is routed through the housing and tied to the pulley. You may need to untie or cut the old knot. Use your pliers to grip the knot if it is tight.
Slowly let the pulley unwind to release the spring tension. Do this in a controlled manner, keeping your fingers clear. Once the tension is fully released, you can remove the old cord completely from the pulley.
Handling The Recoil Spring Safely
The recoil spring is the most delicate part of this repair. It is a coiled piece of metal that can snap or jump out if mishandled.
Wear your safety glasses and gloves during this step. If the spring is housed in a separate compartment, you may not need to remove it. Often, you only need to rewind it.
If the spring has come loose, take a photo of its orientation before removing it. This will help you reinstall it correctly later. A small amount of grease on the spring can help it function smoothly.
Step 3: Install The New Pull Cord
Take your new pull cord and measure it against the old one. It should be the same length. If you need to cut it, leave a little extra for tying the knot.
Feed one end of the new cord through the hole in the starter housing. Then, route it through the handle if your handle is still good. Tie a secure knot at the handle end.
Next, feed the other end of the cord through the hole in the pulley. Pull it through until the handle is snug against the housing. Now, tie a strong knot on the pulley side. A figure-eight or double overhand knot works well.
Step 4: Rewind The Recoil Spring
This is the core of the repair: rewinding the spring inside the starter housing. The goal is to create enough tension to retract the cord smoothly.
Turn the pulley in the direction opposite of the cord pull. This is usually clockwise. You will feel the spring begin to tighten. Make about four to six full rotations, or until the spring is snug.
Hold the pulley in place with one hand. With your other hand, carefully pull the cord out to test the tension. It should retract back into the housing smoothly when you release it. If it doesn’t, you may need to add another half-turn to the spring.
Step 5: Reassemble And Test The Starter
Once the cord is installed and the spring is tensioned, you can reassemble the starter. Make sure the cord is neatly wound around the pulley.
Align the starter assembly back onto the engine. Hand-tighten the bolts first to ensure proper alignment. Then, use your socket wrench to secure them firmly, but do not overtighten.
Reconnect the spark plug wire. Give the pull cord a few test pulls. It should extend and retract easily, engaging the engine to turn over. If it feels good, your repair is complete.
Troubleshooting Common Issues
Sometimes, things don’t go perfectly on the first try. Here are solutions to common problems you might encounter.
- Cord Doesn’t Retract: The spring likely isn’t wound enough. Disassemble and add another turn or two of tension.
- Cord Retracts Too Fast or Jerky: The spring may be overwound or need lubrication. Release a little tension and apply a drop of oil.
- Starter Assembly Won’t Sit Flush: Check that the cord is not bunched up inside. Also, ensure the pulley is aligned with the engine shaft.
- Engine Doesn’t Turn Over: The pulley dogs (the little plastic pieces) might not be engaging. Check them for wear and replace if necessary.
Preventative Maintenance Tips
Taking care of your pull cord can prevent future breaks. Simple habits extend the life of your starter system significantly.
Always pull the cord straight out, not at an angle. A smooth, steady pull is better than a sharp yank. This reduces stress on the cord and the internal spring.
Keep the starter housing clean from grass clippings and debris. Periodically lubricate the spring and pulley mechanism with a light oil. This keeps everything moving freely and prevents rust.
When To Call A Professional
While this is a manageable DIY job, some situations warrant professional help. If the recoil spring is broken or the starter housing is cracked, a mower shop might be the better option.
If you are uncomfortable handling the spring under tension, don’t risk injury. A small fee for a professional repair is worth it for safety. Also, if the engine has other issues beyond the cord, a technician can diagnose them all at once.
Frequently Asked Questions
How Much Does It Cost To Replace A Lawn Mower Pull Cord?
A replacement pull cord typically costs between $5 and $15. If you have a professional do the repair, labor might add another $30 to $50. Doing it yourself is very cost-effective.
Can I Use Any Rope To Replace A Pull Cord?
No, you should use a dedicated lawn mower replacement cord. It is designed to withstand UV exposure, friction, and the constant tension from the spring. Regular rope will fray and break quickly.
Why Does My New Pull Cord Keep Breaking?
Frequent breaks usually indicate a problem with the recoil spring or the pulley. The spring could be too tight, or the pulley may have a rough edge that cuts the cord. Inspect these parts for damage.
How Do I Know If The Recoil Spring Is Bad?
Signs of a bad recoil spring include a cord that does not retract at all, or retracts very slowly and weakly. You might also hear a rattling or grinding noise from the starter housing.
Is It Hard To Rewind A Lawn Mower Spring?
Rewinding the spring requires caution, but it is not technically difficult. The key is to work slowly and keep control of the pulley. Following the step-by-step instructions makes it a straightforward task for most people.