A broken pull cord on a Briggs & Stratton engine leaves you stranded, but replacement parts are readily available. Learning how to replace lawn mower pull cord Briggs and Stratton is a straightforward repair that can save you time and money. With basic tools and a new cord, you can have your mower running again in under an hour.
This guide provides clear, step-by-step instructions. We will cover everything from gathering the right tools to reassembling the starter.
Safety is the first priority. Always disconnect the spark plug wire before beginning any repair to prevent accidental engine starts.
How To Replace Lawn Mower Pull Cord Briggs And Stratton
Replacing the pull cord involves removing the starter assembly from the engine, taking it apart, and installing a new cord. The process is similar across many Briggs & Stratton models. Follow these sections in order for a successful repair.
Tools And Parts You Will Need
Gathering the correct items before you start makes the job smoother. You likely have most of these tools already.
- A new pull cord (check your engine model number for the correct length and thickness)
- Socket set and ratchet (common sizes are 1/2″, 9/16″, and 5/8″)
- Screwdrivers (flathead and Phillips)
- Needle-nose pliers
- Safety glasses
- A pair of gloves
- Clean rag
Step 1: Safety First And Preparation
Always start by ensuring the mower cannot start accidentally. Locate the spark plug wire and firmly pull it off the spark plug. Tuck it away from the plug so it cannot reconnect.
Move the mower to a flat, well-lit work area. Clear away any grass or debris from around the starter housing. This gives you a clean space to work and prevents losing small parts.
Step 2: Removing The Starter Assembly
The starter assembly is the plastic housing that contains the recoil spring and cord. It is held to the engine shroud by three or four bolts.
- Put on your safety glasses.
- Identify the bolts securing the starter cover. They are usually around the perimeter.
- Using the appropriate socket, carefully remove each bolt. Place them in a small container so they don’t get lost.
- Once the bolts are out, gently lift the entire starter assembly straight up and away from the engine. There may be a locating tab, so a slight wiggle might be necessary.
Handling The Recoil Spring
Inside the starter is a tightly wound recoil spring. This spring provides the force to rewind the cord. It is under tension, so handle the assembly with care to avoid it springing open unexpectedly.
Step 3: Disassembling The Starter Housing
Now you need to open the plastic housing to access the old cord and the pulley.
- Lay the starter assembly on your work surface with the pulley facing up.
- You will see a central bolt or nut holding the pulley in place. Some models have a plastic clip instead. Use your socket or screwdriver to remove this center fastener.
- Lift the pulley straight up. Underneath it, you will see the coiled recoil spring. Do not disturb this spring if it is still seated in its track.
- Note how the old cord is knotted and fed through the pulley and the housing’s exit hole. You will replicate this with the new cord.
Step 4: Removing The Old Pull Cord
With the pulley removed, you can take out the broken cord. Untie or cut the knot holding the cord in the pulley. Pull the cord out completely.
Inspect the pulley for any cracks or damage. Also, check the recoil spring is still securely anchored. If the spring has come loose, you may need to rewind it, which is a more advanced step.
Step 5: Installing The New Pull Cord
This is the core of the repair. Take your time to ensure the cord is routed correctly.
- Feed one end of the new cord through the exit hole on the starter housing from the inside out. Pull about 6 inches through.
- Tie a secure knot at the very end of that cord. A figure-eight or double overhand knot works well. The knot must be large enough not to pull back through the hole.
- Now, feed the other end of the cord through the hole in the pulley. Pull it through until the knot you tied rests against the housing.
- Wind the pulley in the direction opposite of the cord’s pull. This pre-winds the spring. Turn it the number of turns specified in your manual, or until you feel moderate resistance.
- While holding the pulley to maintain tension, feed the cord’s free end through the handle and tie another strong knot. Trim any excess cord.
Step 6: Reassembling The Starter
Now you need to put everything back together carefully.
- Slowly release the tension on the pulley, allowing the spring to pull the cord into the housing. The cord should retract smoothly.
- Place the pulley back over the central post, ensuring it engages with the spring tab.
- Reinstall the central bolt or clip and tighten it securely. Do not overtighten, especially on plastic components.
- Give the pull handle a few gentle tugs to test the recoil action. The cord should pull out and retract smoothly.
Step 7: Reinstalling The Starter Assembly
The final step is to put the starter back on your mower.
- Align the starter assembly over the engine shroud, matching any locating tabs with their slots.
- Press down firmly and evenly until the assembly is fully seated.
- Insert and hand-tighten all the mounting bolts. Then, use your socket to tighten them in a criss-cross pattern for even pressure. Avoid stripping the threads.
- Finally, reconnect the spark plug wire to the spark plug.
Testing Your Repair
Your repair is complete. Give the pull cord a firm, steady pull to start the engine. It should engage smoothly and the engine should turn over. If the cord feels gritty or doesn’t retract, you may need to reopen the assembly to check the cord’s routing or the spring.
Common Issues And Troubleshooting
Sometimes, things don’t go perfectly on the first try. Here are solutions to common problems.
Cord Does Not Retract
If the cord stays out, the recoil spring may not be engaged or is broken. You will need to rewind the spring or replace the entire starter assembly if the spring is damaged.
Cord Is Difficult To Pull
A hard-to-pull cord can indicate the cord is rubbing inside the housing or the spring is over-wound. Disassemble and check for smooth routing and proper spring tension.
Starter Rope Keeps Breaking
Frequent breakage suggests the cord is snagging on a sharp edge inside the housing. Inspect the exit hole and pulley for burrs and smooth them with a file if needed. Also, ensure you are using the correct thickness of cord.
Preventive Maintenance Tips
A little care can extend the life of your new pull cord and the entire starter system.
- Always pull the cord straight out, not at an angle.
- Avoid yanking the cord violently; use a smooth, steady motion.
- Periodically clean around the starter housing to prevent grass and dirt from entering.
- Lubricate the starter mechanism with a light spray lubricant once a season, if recommended by the manufacturer.
Frequently Asked Questions
Where Can I Find My Briggs And Stratton Model Number?
The model number is typically stamped on a metal tag attached to the engine’s valve cover or blower housing. It is essential for ordering the correct replacement pull cord.
Can I Use Any Pull Cord For My Briggs And Stratton Mower?
No, it is best to use the specific cord recommended for your engine model. Cords vary in length, diameter, and material. Using the wrong one can lead to poor performance or rapid wear.
How Much Does A Replacement Pull Cord Cost?
A genuine Briggs & Stratton pull cord usually costs between $8 and $15. Universal kits are available for less, but ensure compatibility with your engine.
Is It Hard To Rewind The Recoil Spring?
Rewinding the spring can be tricky because it is under high tension. If the spring has popped out, it is often easier and safer for a DIYer to replace the entire starter assembly rather than attempting to rewind the loose spring.
What If My Starter Assembly Is Cracked Or Damaged?
If the plastic housing is cracked or the pulley is broken, you should replace the complete starter assembly. This is a direct bolt-on part and ensures reliable operation.