How To Replace Lawn Mower Pull Cord

The process of replacing a lawn mower pull cord, while seemingly daunting, can be accomplished with careful attention and the correct tools. This guide provides a detailed, step-by-step instruction on how to undertake this repair.

Preparation and Safety

Prior to commencing any repair work on your lawn mower, ensuring your safety is paramount. The first step involves disconnecting the spark plug wire. This prevents accidental starting of the engine during the repair process. Locate the spark plug, typically found on the engine's side, and firmly detach the wire connecting to it. Once detached, secure the wire away from the spark plug to prevent inadvertent reconnection.

Next, assemble the necessary tools. You will require the following:

• A new replacement pull cord. The correct length and diameter are crucial. Consult your lawn mower's owner's manual or the manufacturer's website to determine the appropriate specifications.
• A socket wrench or a set of wrenches to remove the starter housing. The size of the wrench will depend on the specific bolts securing the housing.
• A flathead screwdriver. This will be used for manipulating the components within the starter assembly.
• A pair of pliers. These will assist in gripping and maneuvering the pull cord.
• Safety glasses. Protect your eyes from debris that may dislodge during the repair.
• Work gloves. These protect your hands and provide a better grip on the tools.

Disassembly of the Starter Housing

The starter housing, often referred to as the recoil starter, is the assembly containing the pull cord and spring mechanism. It is typically located on top of the engine.

Step 1: Removing the Starter Housing. Using the appropriate socket wrench or wrench, carefully remove the bolts or screws securing the starter housing to the engine. Keep these fasteners organized, as you will need them for reassembly. Once the fasteners are removed, gently lift the starter housing away from the engine. Note the orientation of the housing as you remove it; this will aid in proper reinstallation.

Step 2: Accessing the Spool. With the starter housing removed, you will see the spool, which is the component around which the pull cord is wound. Examine the spool for any visible damage, such as cracks or breaks. If the spool is damaged, it may need to be replaced entirely. In many models, a plastic cover or retainer may need to be removed to fully expose the spool. This can often be accomplished using a flathead screwdriver to gently pry the cover off.

Replacing the Pull Cord

Step 3: Removing the Old Cord. Before removing the remnants of the old cord, carefully observe how it is threaded through the starter housing and around the spool. This observation is crucial for correctly threading the new cord. The cord is typically secured in two places: at the handle and at the spool. At the handle, there is usually a knot or a crimped end that prevents the cord from slipping through the handle's opening. At the spool, the cord is often secured by a knot or a clamp within a designated hole. Use pliers or a screwdriver to remove these securing mechanisms. Once both ends are free, pull the old cord out of the starter housing and off the spool.

Step 4: Installing the New Cord. Begin by threading one end of the new pull cord through the designated hole in the spool. Secure the cord in this hole by tying a tight knot or using a clamp if the original cord used one. Ensure the knot is large enough to prevent it from slipping back through the hole. Next, wind the new cord around the spool in the same direction as the old cord was wound. Aim for even winding to prevent binding or uneven pulling. The number of rotations will depend on the length of the cord and the design of the spool.

Step 5: Threading the Cord Through the Housing. After winding the cord around the spool, carefully thread the free end of the cord through the opening in the starter housing and then through the handle. Use pliers to assist in gripping the cord and guiding it through the openings. Ensure the cord runs smoothly and is not twisted or kinked.

Step 6: Securing the Cord at the Handle. Once the cord is threaded through the handle, tie a secure knot at the end of the cord, or use a crimped end if the original cord had one. This knot or crimped end should be large enough to prevent the cord from slipping back through the handle's opening. Pull the handle firmly to test the security of the knot. Trim any excess cord, leaving a small amount of slack. A good rule of thumb is to leave about an inch of extra cord beyond the knot.

Reassembly and Testing

Step 7: Reinstalling the Starter Housing. Carefully align the starter housing with its mounting points on the engine. Ensure the housing is properly seated before reinstalling the bolts or screws. Tighten the fasteners securely, but avoid over-tightening, which could damage the housing or the engine block. Tighten the bolts in a star pattern to ensure even pressure and prevent warping of the housing.

Step 8: Testing the Recoil Mechanism. Before reconnecting the spark plug wire, test the recoil mechanism. Gently pull the pull cord. The cord should extend smoothly and retract fully on its own. If the cord does not retract fully, or if it retracts too slowly, the recoil spring may need adjustment or replacement. This is a more complex repair that may require professional assistance.

Step 9: Reconnecting the Spark Plug Wire. If the recoil mechanism is functioning properly, reconnect the spark plug wire to the spark plug. Ensure the connection is secure.

Step 10: Starting the Mower. Attempt to start the lawn mower by pulling the pull cord. If the engine starts, congratulations; you have successfully replaced the pull cord. If the engine does not start, re-examine all the steps to ensure no errors were made during the repair. Consider consulting the lawn mower's owner's manual or seeking professional assistance if you are unable to resolve the issue.

Troubleshooting Common Issues

The cord does not retract. This is usually caused by a weak or broken recoil spring. In some cases, the spring may simply be dislodged. Replacing the recoil spring is a more complex repair, and may require disassembling the starter housing further.

The cord is difficult to pull. This can be caused by several factors, including a tangled cord on the spool, excessive friction between the cord and the housing, or a lack of lubrication. Ensure the cord is wound evenly on the spool and that there is no debris obstructing its path. A small amount of silicone lubricant can be applied to the cord to reduce friction.

The cord breaks again quickly. This often indicates the use of an incorrect type of cord. Ensure you are using a pull cord specifically designed for lawn mowers, as these cords are more durable and resistant to wear and tear. Also, check for any sharp edges or burrs on the starter housing or spool that could be damaging the cord.

The starter housing is difficult to remove. This can be due to corrosion or seized fasteners. Apply a penetrating oil to the fasteners and allow it to soak for several minutes before attempting to remove them. If the fasteners are severely corroded, they may need to be replaced.

Preventative Maintenance

Regular maintenance can help prolong the life of your lawn mower pull cord and prevent future breakdowns. Consider the following:

• Inspect the pull cord regularly for signs of wear and tear, such as fraying or cracking. Replace the cord before it breaks completely.
• Avoid pulling the cord too forcefully or jerking it abruptly. A smooth, controlled pull is less likely to damage the cord.
• Store the lawn mower in a dry and sheltered location to protect it from the elements.
• Lubricate the pull cord occasionally with a silicone-based lubricant to reduce friction and prevent it from drying out.

By following these steps and tips, you can successfully replace your lawn mower pull cord and keep your lawn mower running smoothly for years to come. Remember to prioritize safety and consult the owner's manual for specific instructions related to your particular model.