How To Replace A
So how do you replace a pull cord? Follow these steps to replace a lawn mower pullcord:
- Remove pull assembly
- Remove old cord
- Replace cord
- Wind spring
- Fit pull handle
- Refit pull assembly
Replacing the cord requires the removal of the pull start assembly. Some manufacturers, like Honda make it easy. One screw, 3 nuts and your in. Other mowers may take a little more work.
If your spring is damaged or unravels, go ahead and buy a whole spring and pulley. They come already assembled, messing around with a recoil spring isn't worth losing an eye.
Thickness of cord is important.
Replacing A Frayed Cord
Measure the new against the old cord.
Lock the spokes of the pulley with a small screwdriver.
Using a sharp pliers, cut the old cord out, feed in and knot the new.
Feed other end into the handle and double knot.
Replacing A Broken Cord
Always pull the plug wire when working on your mower.
Your mower may look different, the symptoms and the repair procedure will be very similar.
To make any repairs the assembly will need to be removed from the mower.
Test the assembly, the pawls shoot out when you pull the cord and retract when the cord recoils.
If your problem is a pull start that just isn't catching and turning over the engine. Simply remove the cap and replace the pawls. Examine all for damage including starter pulley.
If your problem is a damaged spring then the pulley will need to be removed from the assembly.
Most pulleys wont need to be removed from the assembly to replace just the the cord. I find it faster, but you can choose not to, it swings and roundabouts.
Have a container handy for small parts.
The pawls are made from plastic and when worn will cause the pull start to slip.
If you have the old cord, use it as a measure of how much new cord you need. If you don't have it, approx. two and half meters does the job.
Go ahead and take the old cord from the pull handle.
Feed one end of the new pull cord into the cord hole in the rim of the starter pulley.
Pull it through and knot it. I use a lighter to melt the nylon cut end, tidies it up.
Wind the pull cord around the rim of the starter pulley, anti-clockwise with spring facing down.
It's helpful to mark the rim where the pull cord ends with white paint.
Helps finding it later.
Align the spring hook with the metal tab on the pull start assembly housing, you'll be fitting this blind.
Now seat it, confirm its seated by turning it anti-clockwise, you should feel the spring resistance.
Fit both pawls, cap and tighten bolt.
Now wind the starter pulley, anti-clockwise three revolutions and align your white mark with the cord hole in the assembly housing.
You can't let go or the spring will unwind.
While holding the loaded starter pulley, or locking it with a screwdriver, locate the cord end which you marked earlier.
Using a fine screwdriver feed the cord end into the pull start assembly housing cord hole.
Pull the cord through the hole and wrap it around your hand to prevent it recoiling back in.
Burning and clipping it into a point helps the feeding process.
Feed the remaining end into the pull handle, use a fine screwdriver to help guide it.
Rubbing a small amount of oil on the end of pull cord helps it slip through.
When through double knot.
Pull to test, the Pawls should shoot out when the cord is pulled and retract when the cord rewinds.
Nice work, refit assembly, your done!
Pull Cord Troubleshooting
Cord Hard to Pull
Check that the bail lever is releasing the flywheel brake.
If not, check cable for adjustment.
Grass and stuff stopping the blade turning, simple fix here.
Too much oil or oil that's too heavy will cause the pull cord to be heavy.
Needle and float together control gas flow to the fuel bowl.
Valve lash should be checked every season, it's usually overlooked.
Check the flywheel shear key.
Replacement engines are not difficult to fit but sometimes it's better to just buy a new mower.