A broken pull cord can leave your mower useless, but the repair is often simpler than it appears. Learning how to repair a lawn mower pull cord is a fundamental skill that saves you time and money. This guide provides clear, step-by-step instructions to get your mower running again.
You will need some basic tools and a bit of patience. The process involves accessing the recoil starter assembly, replacing the cord, and winding the spring. We will cover everything from diagnosis to the final pull test.
How To Repair A Lawn Mower Pull Cord
The repair process follows a logical sequence. First, you gather tools and parts. Then, you safely disassemble the starter. Finally, you install the new cord and reassemble the unit. Let’s break it down into manageable steps.
Tools And Materials You Will Need
Before you start, collect these items. Having everything ready makes the job smoother and safer.
- A replacement pull cord (check your mower’s manual for length and thickness)
- Socket set and screwdrivers (flathead and Phillips)
- Needle-nose pliers
- Safety glasses and work gloves
- A sturdy work surface
- Light machine oil or grease
- A cord grip or suitable knot-tying knowledge
Safety First: Preparing Your Mower
Always prioritize safety. A simple mistake can lead to injury or further damage to the mower.
Disconnect The Spark Plug
This is the most critical step. Locate the spark plug wire and firmly pull it off the plug. This prevents the engine from accidentally starting while you work on it.
Drain The Fuel Or Stabilize The Mower
If you will be tipping the mower, drain the fuel from the tank and carburetor first. Alternatively, you can stabilize the mower so the fuel tank remains upright to avoid leaks.
Clean The Work Area
Remove any grass clippings and debris from around the starter assembly. This prevents dirt from falling into the engine during disassembly.
Step-By-Step Repair Instructions
Follow these steps carefully. Take pictures with your phone during disassembly if you are unsure about reassembly later.
Step 1: Remove The Starter Assembly
The recoil starter is usually held on by three or four bolts. Use your socket set to remove these bolts. Gently lift the entire starter assembly away from the engine block. Be careful not to jostle it excessively, as the internal spring is under tension.
Step 2: Release The Old Cord And Spring Tension
Place the assembly on your work surface. Slowly pull out the remaining piece of the old cord until you feel resistance. This is the spring wanting to rewind. Let the handle come to rest against the starter housing.
Now, you must carefully release the spring’s tension. Using your screwdriver, locate the small retaining clip or tab on the pulley. Gently pry it up while slowly letting the pulley spin counter-clockwise to unwind. The goal is to have the spring relax completely so the pulley spins freely.
Step 3: Remove The Old Cord And Handle
Once tension is released, you can remove the old cord. Untie or cut the knot holding the cord to the pulley. Then, slide the cord out of the eyelet in the starter housing. Next, address the handle. Most handles have a simple knot underneath a plastic cover. Pry off the cover, untie the knot, and remove the old cord.
Step 4: Prepare And Install The New Cord
Cut your new pull cord to the same length as the old one. If the old cord is missing, a standard length is about four to five feet. Melt the ends of the nylon cord lightly with a lighter to prevent fraying.
- Thread one end of the new cord through the hole in the starter handle and tie a secure knot, like a double overhand knot. Snap the cover back on.
- Feed the other end of the cord through the eyelet on the starter housing and then through the hole in the pulley.
- Tie a solid knot on the underside of the pulley. Leave a small tail, but trim any excess to prevent interference.
Step 5: Wind The Spring And Recoil The Cord
This is the trickiest part. You need to wind the spring by turning the pulley. Rotate the pulley in the direction opposite of the cord pull (usually clockwise) until you feel moderate resistance. This winds the spring. Do not overwind it.
Now, while holding the pulley, carefully pull the cord out and wrap it neatly around the pulley groove. Leave just enough cord out to allow the handle to rest about an inch from the housing when not in use.
Step 6: Reinstall The Starter Assembly
Align the starter assembly back onto the engine. Insert and tighten the mounting bolts evenly. Do not overtighten them, as you could strip the threads or crack the housing. Give the cord a few slow, test pulls to ensure it retracts smoothly.
Step 7: Final Safety Check And Test
Reconnect the spark plug wire. With the mower on a flat surface, give the cord a firm, full pull. The engine should turn over. If it starts, let it run for a minute to ensure everything is working correctly. Listen for any unusual noises from the starter area.
Common Problems And Troubleshooting
Sometimes, the repair doesn’t go perfectly on the first try. Here are solutions to common issues.
The Cord Does Not Retract
This usually means the recoil spring is not engaged or is broken. You may need to reopen the assembly and check that the spring’s inner hook is properly seated in the center post. If the spring is broken, you’ll need to replace the entire recoil spring kit.
The Cord Retracts Too Forcefully Or Jerkily
This indicates the spring was overwound during installation. You must release tension and rewind it with fewer turns. About 2-3 full rotations of the pulley after the spring first engages is typically sufficient.
The Cord Frays Or Breaks Quickly After Repair
Check the eyelet on the starter housing for sharp edges. Smooth it out with a small file or sandpaper. Also, ensure you are using the correct thickness of cord specified for your mower model. A cord that is too thin will ware out fast.
Preventive Maintenance Tips
A little care can prevent future pull cord failures. Incorporate these habits into your mower maintenance routine.
- Lubricate the spring and pulley occasionally with a light machine oil. A drop or two is enough.
- Always pull the cord straight out. Angled pulls cause uneven wear on the cord and the eyelet.
- Store your mower in a dry place to prevent rust on the internal spring and mechanisms.
- Clean around the starter housing regularly to keep grass and dirt from entering.
When To Call A Professional
While this repair is very DIY-friendly, some situations warrant professional help. If the recoil spring is shattered or the starter housing itself is cracked, a replacement assembly might be the best solution. If you are uncomfortable with the spring tension steps, a small engine shop can complete the repair quickly and safely. It’s also wise to seek help if the engine has other, more complex issues beyond the pull cord.
Frequently Asked Questions
What Is The Average Cost To Fix A Lawn Mower Pull Cord?
If you do it yourself, the cost is just for the replacement cord, usually between $5 and $15. If you take it to a repair shop, labor might bring the total to $50 to $80, depending on your location and the mower model.
Can I Use Any Type Of Rope For A Lawn Mower Pull Cord?
No, you should not. Use only a designated lawn mower pull cord or a high-quality nylon cord of the same diameter. Regular rope can fray quickly, lacks the necessary flexibility, and may not hold knots securely, posing a safety risk.
How Often Should A Pull Cord Be Replaced?
There’s no set schedule. A pull cord should last for many years with proper use. Replace it when you notice significant fraying, when it becomes difficult to pull, or immediately after it breaks. Inspecting it at the start of each mowing season is a good practice.
Why Does My Pull Cord Stick Or Feel Hard To Pull?
A sticking cord is often a sign of a problem beyond the cord itself. It could indicate a seized engine, a damaged recoil mechanism, or a binding pulley. First, ensure the engine isn’t locked up by trying to turn the blade by hand (with the spark plug disconnected). If the engine turns freely, the issue is likely inside the starter assembly.
Is It Difficult To Repair A Recoil Starter Spring?
Replacing the recoil spring is more challenging than just replacing the cord. The spring is under significant tension and can be dangerous if not handled carefully. If you are not confident, replacing the entire starter assembly as a unit is often a safer and simpler alternative for most DIYers.