Your lawn mower’s pull cord is an essential component that allows you to start the engine. Over time, the pull cord can become frayed, stretched, or even snap, leaving you with a non-functional lawn mower. Replacing the pull cord is not a difficult task and can be completed in just a few steps. This guide will provide you with detailed instructions on how to replace the pull cord on your lawn mower, ensuring that your lawn care routine is uninterrupted.
Before you begin, gather the necessary tools and materials. You will need a new pull cord, a pair of pliers, a screwdriver, and a pair of needle-nose pliers. Once you have gathered your tools, find a well-lit workspace and place your lawn mower on a stable surface. Disconnect the spark plug wire from the spark plug to prevent accidental starting. Then, proceed with the following steps:
Locate the pull cord housing, which is typically located on the side of the engine. Remove the screws that hold the housing in place and carefully lift it off. Inside the housing, you will find the old pull cord wound around a pulley. Use the needle-nose pliers to unhook the old pull cord from the pulley and discard it. Next, thread the new pull cord through the hole in the housing and attach it to the pulley. Wind the new pull cord around the pulley in the same direction as the old cord was wound. Finally, reattach the housing to the engine and tighten the screws. Your lawn mower is now ready to start with its new pull cord.
Selecting the Appropriate Pull Cord
Selecting the appropriate pull cord for your lawn mower is crucial for efficient mowing. Here are some key considerations to keep in mind:
Material:
The material of the pull cord directly impacts its durability and longevity.
- Nylon: A popular choice due to its strength, flexibility, and resistance to abrasions.
- Polyethylene: Offers similar properties to nylon but tends to be slightly less durable.
- Steel: Durable and can withstand high tensile forces but may rust in humid environments.
Length:
The length of the pull cord should be appropriate for the size of your lawn mower.
- Small mowers: Typically require cords between 12-18 inches.
- Medium mowers: Optimal cord length is between 18-24 inches.
- Large mowers: May need cords up to 30 inches or more to ensure adequate reach.
Diameter:
The diameter of the pull cord determines its strength and grip.
- Thin cords: Less than 1/8 inch in diameter may be suitable for small mowers but offer less durability.
- Medium cords: Around 1/8 inch in diameter provide a good balance of strength and handling.
- Thick cords: Exceeding 1/8 inch in diameter are suitable for larger mowers and heavy-duty applications.
Design:
Some pull cords feature additional designs for enhanced functionality or safety.
- Handle grips: Ergonomically designed handles provide a comfortable grip, reducing fatigue during extended use.
- Safety features: Cords with safety clips or guards prevent accidental startups or injuries caused by cord entanglement.
By considering these factors, you can select the appropriate pull cord that meets the specific requirements of your lawn mower, ensuring smooth and efficient operation.
Safety Precautions Before Replacement
Before embarking on the repair, observe these crucial safety measures to prevent accidents and ensure a smooth process:
Disconnect the Spark Plug
Locate the spark plug wire and carefully disconnect it from the spark plug. This simple step eliminates the risk of electric shock when handling the pull cord mechanism.
Allow the Engine to Cool
After disconnecting the spark plug, give the engine ample time to cool down. Hot engine components can cause burns if touched inadvertently. Wait until the engine is completely cool to the touch before proceeding.
Wear Gloves
Protect your hands from sharp edges and dirt by wearing a pair of sturdy work gloves. Gloves provide an extra layer of protection, especially when working with rusty or frayed components.
Secure the Mower
To prevent the mower from rolling or moving unexpectedly, engage the blade brake lever or place a heavy object, such as a brick, behind the wheels. This added stability ensures a safe working environment.
Disassembling the Mower to Access the Pull Cord
To prepare for the pull cord replacement, you must first disassemble the lawn mower to gain access to the damaged cord. Follow these steps:
- Unplug the Spark Plug:Locate the spark plug and disconnect it by pulling the wire cap off. This safety measure prevents accidental starting of the mower during disassembly.
- Remove the Air Filter Housing:Find the air filter housing, which is usually a plastic or metal cover. Unfasten the screws or clips holding it in place and lift it off to expose the carburetor.
- Detach the Carburetor:Disconnect the fuel line from the carburetor by squeezing the clamps and pulling it loose. Next, locate the throttle cable and unhook it from the carburetor. Finally, remove the bolts or screws holding the carburetor in place and carefully lift it off.
- Unscrew the Starter Assembly:Once the carburetor is removed, you’ll see the starter assembly, which houses the pull cord mechanism. Locate the bolts or screws securing the assembly to the engine and unscrew them to detach it.
Accessing the Pull Cord
With the starter assembly removed, you now have direct access to the pull cord. Inspect the cord carefully to identify any frayed or broken areas. To simplify the replacement process, we recommend creating a loop at the end of the old cord and attaching it to the new one. This will act as a guide to pull the new cord through the assembly as you unravel the old one.
| Component | Description |
|---|---|
| Spring | Provides tension to the pull cord and retracts it after use. |
| Idler Pulley | Guides the pull cord and helps it move smoothly. |
| Pulley | Attaches to the crankshaft and engages when the pull cord is pulled, starting the engine. |
By following these steps, you can access the pull cord and proceed with its replacement.
Detaching the Old Pull Cord
1. Locate the Pull Cord Socket:
Identify the socket where the pull cord is attached to the engine. It’s typically a small, cylindrical housing located near the starter mechanism.
2. Grasp the Pull Cord Handle:
Firmly grip the handle of the pull cord, located at the end of the cord.
3. Pull and Inspect the Cord:
Pull the cord gently to create some tension. Examine the cord for any visible damage, such as fraying, cracks, or knots.
4. Detach the Pull Cord Handle:
- For Socket with a Retaining Spring:
Use a pair of pliers to compress the spring inside the socket. This will release the handle from the socket. Alternatively, some sockets have a small latch that can be pushed or pulled to release the handle. - For Socket with a Screw-On Handle:
Rotate the handle counterclockwise to unscrew it from the socket. Ensure the engine is turned off before attempting this step.- For Socket with a Pull-Out Handle:
Simply pull the handle straight out of the socket. It may require some force to detach.5. Remove the Pull Cord from the Socket:
Once the handle is detached, gently pull the cord out of the socket. Avoid excessive force, as it may damage the socket or the cord.Installing the New Pull Cord
5. Thread the Cord and Knot the Ends
Feed the new pull cord through the handle, pulley housing, and engine shaft. Make sure it runs smoothly without tangling or binding. Hold one end of the cord firmly and carefully pull the other end through until it reaches the starter cup on the engine.
Once the cord is fully threaded, carefully knot the ends together to secure the cord in place. However, do not overtighten the knot, as this can weaken the cord. To ensure a secure knot, double-knot the ends by repeating the knotting process twice.
Check the length of the pull cord by pulling it fully out. It should be long enough to allow for comfortable starting, but not so long that it gets tangled or poses a tripping hazard.
Knot Type Recommended for Pull Cords Square Knot Yes Overhand Knot Not recommended Surgeon’s Knot Yes (for stronger knot) After knotting the cord, trim any excess length to prevent potential tangles. Pull on the cord a few times to ensure it operates smoothly and the engine starts properly.
Replacing the Starter Handle Assembly
Replacing the starter handle assembly is a straightforward repair that typically requires the following steps:
1. Safety Precautions
Always disconnect the spark plug wire before performing any repairs on your lawn mower. Wear gloves and safety glasses for protection.
2. Remove the Starter Cover
Locate the starter cover on the side of the engine and remove the bolts or screws that hold it in place. Carefully lift off the cover.
3. Disconnect the Pull Cord
Find the pull cord and disconnect it from the recoil starter assembly. You may need to pull the cord out slightly to access the connection.
4. Remove the Starter Assembly
Unbolt the starter assembly from the engine. There are typically one or two bolts that hold it in place.
5. Remove the Recoil Starter
Remove the recoil starter from the starter assembly. This may require separating the two halves of the starter with a screwdriver.
6. Replace the Pull Cord
Wind the new pull cord onto the recoil starter in a clockwise direction. Ensure that the cord is wound tightly and evenly. There are typically four anchors where the cord is attached to the starter, one for each of the four corners. Insert one end of the cord into one of the anchors and pull it all the way through. Fold over the end of the cord and insert it back into the same anchor. Repeat for the remaining three corners.
Once the pull cord is wound, cut off any excess length. Tie a knot in the end of the cord and pull it tight against the recoil starter.
7. Reassemble the Starter Handle Assembly
Place the recoil starter back into the starter assembly and secure it with the bolts. Attach the pull cord to the recoil starter and connect the handle to the pull cord. Replace the starter cover and tighten the bolts or screws.
Adjusting the Tension and Length of the Pull Cord
After replacing the pull cord, it’s crucial to adjust the tension and length to ensure smooth operation. Follow these steps to make precise adjustments:
1. Determine Optimal Cord Length:
Position yourself behind the mower and pull the starter handle until the cord is fully extended. Note the length at which the engine starts. This is your optimal cord length.
2. Adjust the Guide Wire:
Locate the guide wire that directs the pull cord through the frame. Adjust its position on the cleat or guide mount to match the optimal cord length.
3. Adjust the Knot or Stop:
Locate the knot or stop at the end of the pull cord. Reposition it accordingly to ensure that the cord is taut but not excessively tight.
4. Check for Obstructions:
Inspect the pull cord housing and guide wire for any obstructions that might impede smooth retraction. Remove any debris or misalignment.
5. Cycle the Pull Cord:
Pull the starter handle several times to test the tension and retraction smoothness. If necessary, make further adjustments to the guide wire or stop.
6. Secure the Pull Cord:
Once the tension and length are satisfactory, secure the pull cord in place. Tie a firm knot or use a cable clamp to prevent the cord from slipping out.
7. Final Check:
Start the mower and observe the pull cord operation. The cord should retract smoothly and without excessive resistance. If any issues persist, inspect for damage or further misalignment in the recoil starter system.
Reassembling the Mower
8. Reattaching the Pull Cord
This is the most crucial step in the entire process, as improper reattachment can result in the pull cord becoming entangled or even breaking. Follow these steps meticulously:
Detailed Steps:
- Identify the Pull Cord Groove: Locate the U-shaped groove on the mower’s engine shroud where the pull cord runs.
- Insert the Cord into the Groove: Carefully insert the cord into the groove, starting from the side opposite the recoil housing.
- Align the Cord with the Pulley: Ensure that the cord is aligned with the pulley inside the recoil housing.
- Feed the Cord Through the Hole: Pass the cord through the small hole in the recoil housing.
- Tighten the Screw: Use a screwdriver to tighten the screw holding the recoil housing in place. This will secure the pull cord in the groove.
- Test the Tension: Pull the cord gently to check if there is sufficient tension. If it’s loose, tighten the screw further.
- Wind the Cord: Holding the starter handle, slowly wind the pull cord around the pulley in a clockwise direction.
- Secure the Recoil Housing: Tighten the bolts that hold the recoil housing in place, ensuring the housing is firmly attached to the engine shroud.
- Retract the Pull Cord: Slowly pull the starter handle towards you to retract the pull cord inside the recoil housing.
- Check for Function: Start the mower and pull the cord to ensure it functions properly.
Testing the New Pull Cord
After installing the new pull cord, it’s crucial to test its functionality. Here’s a step-by-step guide to ensure the cord is working properly:
- Fuel Valve Position: Ensure the fuel valve is closed or the engine is turned off before testing.
- Grasp the Pull Cord Handle: Grip the pull cord handle firmly, maintaining a comfortable grip.
- Steady Pull: Pull the cord steadily and smoothly, avoiding jerking or sudden movements.
- Check Resistance: As you pull, you should feel some resistance from the recoil spring. If there’s minimal or no resistance, it may indicate a weak or incorrect spring.
- Engine Response: Observe the engine’s response. If the engine starts and runs smoothly, the pull cord is working properly.
- Smooth Operation: The pull cord should retract easily and smoothly into the housing after it’s been released.
- Rewind Speed: The cord should rewind at a moderate speed, not too fast or too slow.
- Starter Pulley Alignment: Check if the starter pulley is aligned correctly and not causing any friction or resistance as the cord pulls.
- Handle Grip and Ergonomics: Ensure the pull cord handle is comfortable to grip and that it won’t cause any discomfort during extended use.
- Repeat Test: Repeat the pulling process several times to assess the consistency of the cord’s performance and to check for any hiccups or irregularities.
Troubleshooting Tips
If the new pull cord is not working properly, consider the following troubleshooting tips:
Issue Possible Cause Solution Cord not pulling Recoil spring weak or not installed correctly Replace or adjust the recoil spring Cord pulling too easily Recoil spring too weak or broken Replace the recoil spring Cord retracts too slowly Housing not clean or lubricated Clean and lubricate the housing Pull cord handle uncomfortable Grip worn out or handle design unsuitable Replace the handle or choose a more ergonomic option Maintaining and Storing the Pull Cord for Optimal Performance
A well-maintained pull cord is essential for starting your lawn mower effortlessly. Here are some tips to keep it in optimal condition:
Regular Cleaning
Dirt and debris can accumulate on the pull cord, causing it to become stiff or break. Regularly wipe it down with a clean, dry cloth to remove any buildup.
Lubrication
A small amount of lubricant can help the pull cord move smoothly and reduce friction. Apply a few drops of a lightweight oil, such as WD-40 or silicone spray, to the cord and let it soak in.
Coiling Correctly
When not in use, coil the pull cord neatly and securely. Avoid coiling it too tightly, as this can damage the cord’s inner strands.
Store in a Cool, Dry Place
Extreme heat or moisture can damage the pull cord. Store it in a cool, dry place to prevent warping or fraying.
Inspect Regularly
Check the pull cord regularly for any signs of damage, such as fraying, cracking, or stiffness. Replace it immediately if you notice any issues.
10. Troubleshooting Common Pull Cord Issues
Issue Possible Cause Solution Cord breaks when pulled Damaged cord or weak spring Replace cord or spring Cord retracts slowly Sticky or dry lubricant Lubricate cord or replace spring Cord does not rewind Broken or jammed return spring Inspect and replace spring Cord pulls but does not engage Misaligned or broken starter pawl Adjust or replace pawl Cord pulls hard Damaged recoil housing or flywheel Inspect and repair or replace How to Replace the Pull Cord on a Lawn Mower
Replacing the pull cord on a lawn mower is a relatively simple task that can be accomplished with a few basic tools. The following guide will provide you with step-by-step instructions on how to complete this task.
Required Tools
- New pull cord
- Screwdriver
- Pliers
- Allen wrench (if necessary)
Instructions
- Safety First: Ensure the lawn mower is turned off, the spark plug is disconnected, and the mower is cool before beginning any work.
- Locate the Pull Cord Assembly: The pull cord assembly is typically located on the side or top of the mower engine.
- Disconnect the Pull Cord: Locate the screw or bolt that secures the pull cord to the recoil starter. Remove the screw or bolt and disconnect the pull cord.
- Remove the Recoil Starter Cover: In some cases, the recoil starter cover may need to be removed to access the recoil spring. Use a screwdriver or Allen wrench to remove the cover.
- Replace the Recoil Spring: If the recoil spring is damaged, it will need to be replaced. Use pliers to remove the old spring and install the new spring.
- Reattach the Pull Cord: Attach the new pull cord to the recoil starter. Insert the cord through the hole on the recoil starter and secure it with the screw or bolt.
- Adjust the Cord Length: Adjust the length of the pull cord so that there is approximately 6-8 inches of slack when the cord is fully extended.
- Lubricate the Cord: Apply a small amount of grease to the pull cord to prevent future wear and tear.
- Reassemble the Pull Cord Assembly: Reinstall the recoil starter cover, if necessary, and reconnect the pull cord assembly to the lawn mower.
- Test the Pull Cord: Start the lawn mower and pull the cord to ensure it is working correctly.
People Also Ask
How do I know if my pull cord is broken?
If the pull cord is frayed, snapped, or does not recoil properly, it is likely broken.
Can I replace the pull cord myself?
Yes, replacing the pull cord on a lawn mower is a relatively straightforward task that can be done by most homeowners with basic tools.
How often should I replace the pull cord?
The pull cord should be replaced as needed, typically every few years or as it starts to show signs of wear or damage.
Where can I buy a replacement pull cord?
Replacement pull cords can be purchased at most hardware stores and home improvement centers.
- For Socket with a Pull-Out Handle:
