If your lawn mower pull cord is starting to fray, it’s only a matter of time before it will snap completely. Or you may be reading this article because it already did. A broken lawn mower pull cord is a pretty common problem that most lawn mower owners will face at some point or another. But, not to worry, with the right tools and parts, you can get your pull cord fixed in 30 minutes and get back to mowing. Here is everything you need to know on how to fix a lawn mower pull cord.
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The Process of Fixing a Lawn Mower Pull Cord
There are five key steps to fix the pull cord on a lawn mower:
- Remove the recoil starter assembly from the lawn mower.
- Remove the old cord.
- Install a new cord into the recoil starter and handle.
- Wind the cord around the recoil pulley and ensure the spring is tensioned.
- Reattach the recoil starter to your lawn mower.
Tools & Materials Needed to Fix a Lawn Mower Pull Cord
One of the most important elements of replacing a lawn mower pull cord is to ensure that you use a cord that is the right length and thickness. A cord that is too thick may not fit in the lawn mower pull cord assembly, and a thin cord may not be strong enough to start the engine. Also, a cord that is too short will not rotate the engine long enough to start the engine, whereas a cord that is too long will dangle out of the lawn mower pull cord assembly and potentially get caught up in the moving parts. If you are unsure what cord to use, you can always look in your owner’s manual for the cord reference.
What You’ll Need to Fix Lawn Mower Pull Cord
- Replacement Cord (Example Product)
- Box Cutter
- Screwdriver
- Pliers (Needle Nose or standard)
- Nut Driver
How to Replace a Lawn Mower Pull Cord (summary)
Now that you have gathered all your tools and parts, let’s go over how to replace your mower’s pull cord. First, I’ll list the steps and then break them down in more detail below.
- Remove the Spark Plug Cable
- Remove the Starter Assembly from the Top of the Lawn Mower
- Pull the Old Cord from the Recoil Starter Assembly
- Clamp the Pulley in Place
- Detach the Old Rope from the Pulley
- Remove the Old Rope from the Pull Handle
- Add Tension to the Pulley if Needed
- Align the Pulley to the Opening in the Recoil Assembly
- Clamp the Pulley in Place
- Thread the Cord Through the Pulley & Starter Housing
- Tie a Knot at the End of the Cord
- Pull the Cord & Position the Knot
- Tie a Knot in the Center of the Rope
- Remove the Clamp from the Pulley
- Thread the Cord Through the Handle
- Knot the End of the Cord
- Remove the Knot in the Center of the Rope
- Test the Starter Cord
- Install the Starter Assembly onto Your Mower
- Reattach the Spark Plug
- Test the Assembly
Step-by-Step Guide to Fixing Your Mower’s Pull Cord
Remove the Spark Plug Cable
First, remove the spark plug cable from the spark plug so that the engine isn’t able to start unexpectedly.
Remove the Starter Assembly from the Top of the Lawn Mower
Next, use your nut driver to remove the fixing holding the recoil starter to the top of your lawn mower’s engine. Depending on your mower’s design, you might need to remove the engine cover first.
Pull the Old Cord from the Recoil Starter Assembly
Then, pull the cord from the recoil starter assembly and allow the pulley to tension the recoil spring. If your cord has snapped already, turn the pulley until the recoil spring is fully tensioned.
Clamp the Pulley in Place
With the spring fully tensioned, use a clamp on the assembly to hold the pulley in place.
Detach the Old Rope from the Pulley
Next, remove the old rope from the pulley. You can use a pair of needle nose pliers to help you pull the knot from its seated position inside the pulley.
Remove the Old Rope from the Pull Handle
Then remove the old cord from the pull handle. You might find that the knot is covered with a plastic cap. If this is the case, use a flathead screwdriver to remove the cap, then pull the cord from the handle.
Add Tension to the Pulley if Needed
If the pulley has moved during this process, apply tension to the pulley until it is unable to tighten any further.
Align the Pulley to the Opening in the Recoil Assembly
Next, release the tension on the pulley until the hole in the assembly housing and the hole in the pulley align.
Clamp the Pulley in Place
With the pulley and housing in alignment, clamp the pulley in place.
Thread the Cord Through the Pulley & Starter Housing
Next, thread your cord through the starter housing and then through the pulley.
Tie a Knot at the End of the Cord
Now, grab the end of the cord from inside the pulley and tie a knot. Try to get the knot as close to the end of the cord as possible. Then trim off any excess cord using your box cutter.
Pull the Cord & Position the Knot
Then pull the cord so that the knot sits against the pulley. You might find that the pulley has a small recess for the knot to sit inside. Make sure the knot is in place and doesn’t come into contact with the starter housing.
Tie a Knot in the Center of the Rope
Next, tie a large, loose knot in the center of the cord.
Remove the Clamp from the Pulley
Remove the clamp and allow the recoil to take up the slack. Once the knot comes into contact with the housing, the pulley will stop rotating.
Thread the Cord Through the Handle
Next, thread the end of the cord through the bottom of the handle.
Knot the End of the Cord
Tie a knot at the end of the cord and remove any excess cord beyond the knot. Then pull the cord so that the knot sits inside the handle.
Remove the Knot in the Center of the Rope
Once the handle is in place, remove the knot you placed in the center of the cord. When you remove the knot, the cord should retract until the handle rests against the recoil housing.
Test the Starter Cord
With the new cord installed in the lawn mower pull cord assembly, you can go ahead and give it a try. You want the cord to extend and retract fully without any problems.
Install the Starter Assembly to Your Mower
Next, line up the recoil starter assembly with the starter cup located on the top of the flywheel. Then install the housing fixings to secure the starter in place.
Reattach the Spark Plug
Now that you have finished replacing the pull cord, you can go ahead and reattach the spark plug cable.
Test the Assembly
Finally, give the lawn mower pull cord assembly a try by starting your lawn mower.
