Picture this: you’ve put on your sunnies and slopped on some sunscreen. You’ve got a cold drink waiting for you after a morning of mowing the lawn.
You get the mower out, ready for a few hours of yard work – and as soon as you start it, the starter rope comes right off.
The cause? A broken cord. Thankfully, this is an easy fix that requires some DIY repair work and a quick trip to a tool store.
How to replace a pull cord on a lawn mower? You’ll need to remove the starter assembly and take out the old rope. After that, wind the pulley and feed the new cord into the system. Let the pulley wind back, then attach the free end of the cord to the handle while maintaining some tension.
Don’t tie yourself into knots over a broken lawn mower pull cord! Replacing the rope is easy, and lets you prolong the lifespan of your old, reliable partner.
Broken vs. Stuck Pull Cord
First off, make sure to check the starter rope is actually broken, not stuck! You don’t want to waste time and effort only to find out the cord is still usable.
If your mower pull cord is stuck, it could be caused by:
- Jammed mower blades
- A rusty starter assembly
- Faulty recoil mechanism
- Hydrolocking
Give your mower a once-over, from the deck to the engine. A stuck cord is a straightforward fix once you know the cause.
But if you’ve checked the recoil or rewind assembly and found a broken cord, then it’s time to fit a new one.
When to Replace a Lawn Mower Pull Cord
Checking on the condition of the pull cord (also called a starter rope, cable, or ripcord) is an essential part of lawn mower maintenance.
The sooner you notice any damage, the sooner you can replace the old cord! After all, it’s easier to replace a damaged (but intact) cord versus a broken one.
You should replace your mower cord if you find:
- Fraying or partial unravelling
- Small tears
- Thinning material
- Debris or residue (like sap) that cannot be removed
- Knots that won’t untangle
Inspect the rewind assembly as well! Sometimes the cord itself is fine, but the rewind system is broken – and will need replacing.
How to Pick a Starter Cord Replacement
When selecting a replacement cord, you’ll need to know two things: rope length and diameter.
Too-thick cords will have a hard time moving through the rewind assembly, while too-thin cords will wear out quickly or become knotted.
It’s best to buy a cord replacement that’s identical to the old one – these are called OEM parts (Original Equipment Manufacturer).
Most lawn mower brands will sell OEM replacement cords for their models.
If your model has been phased out, or the OEM part isn’t available, find the specs in the owner’s manual. You can also check your mower’s model number and look up the appropriate cord on the brand website.
Follow the specs to find a compatible pull cord replacement.
How to Replace a Lawn Mower Pull Cord
Always start by switching off your lawn mower and letting it cool down. Remove the spark plug and wire to prevent accidental starts, and work on a flat surface.
Some tools you’ll need to replace a mower pull cord include:
- Screwdrivers
- Needle-nose pliers
- Work scissors
- Work gloves and eye protection
- Lighter (optional)
Follow your owner’s manual to unscrew the starter housing and access the rewind assembly. Some models have a plastic cap (or “shroud”) on top, which you’ll need to take off first.
Place the screws in a small container or on top of a clean rag so you can find them again later.
Alternatively, some mowers have bolts or rivets instead of screws holding the starter housing. Switch to the appropriate tools to remove them.
Quickly wipe off any dirt or debris under the housing or along the ridges.
Removing the old pull cord
If the rope is sticking out of the starter housing, just pull at it. Otherwise, use the needle-nose pliers to retrieve the end of the rope from inside the hole in the assembly.
On some models, you may have to manually turn the assembly to help the cord unwind.
Be careful when pulling, as the cord could snap back and injure you if let go!
When you’ve pulled the rope as far as it goes, wedge a screwdriver into the pulley to prevent it from rewinding. The holes in the pulley and housing should align.
Cut or untie the other end of the old pull cord from the handle. Then, if your new cord is too long, measure it against the length of the old cord and add a few extra centimetres before you cut.
TIP: Away from the mower, use a lighter to “melt” or “seal” the edges of the new pull cord – this makes it easier to thread and prevents fraying.
Feeding the new pull cord
Remove the screwdriver and let the pulley reset, since you’ll need to rewind the recoil spring. Turn the pulley in the same direction as the rope would go out until you feel resistance.
Let it reverse just enough that the hole in the pulley lines up with the one in the recoil housing.
Feed one end of the rope through the hole, until it comes out the other side, then tie a knot at the exposed end. You can use the lighter to melt the knot a bit to prevent it from coming undone.
If the new pull cord comes with its own handle, simply set it in its resting place. Remove the screwdriver and (carefully!) let the pulley rewind completely. Tug it a few times to make sure it works.
Otherwise, remove the screwdriver and let the pulley rewind. Make sure there’s enough rope exposed so you can thread it through the starter housing and attach it to the handle.
Take the free end of the new rope and thread it through the handle. Give it a little tug to introduce some tension, then fix it with a tight knot (you can melt it for extra security). That slight pull ensures the cord won’t go slack and cause problems.
This is doubly important for lawn mowers where the cord goes all the way up to a pull handle. When tying the knot, place the rope handle in its resting place so you have the correct tension.
Cut any excess rope, release the handle, and let the rope wind itself back. Then give it a few pulls to ensure everything’s in working order.
Reinstall the rewind assembly and reattach the spark plug. Prime the mower if necessary, then yank the pull cord to start the mower.
FAQs about Lawn Mower Pull Cords
Here are a few things that are good to know before you replace your lawn mower pull cord!
Why is there no tension on my lawn mower pull cord?
Two reasons: either the pull cord is broken, or it’s come off the pulley.
If the cord is misaligned or otherwise removed from the pulley, follow the steps to access the rewind assembly. Then use a screwdriver or pair of pliers to realign the rope with the pulley.
If the cord is broken, you’ll need to replace it!
How much does it cost to replace a lawn mower pull cord?
So long as you already have the basic tools, you’ll only have to pay the cost of a new cord – typically around $10–25, depending on the mower brand and model.
If you need to replace the rewind assembly as well, it’ll cost more (typically an additional $25–50).
How do you tie a pull cord on a lawn mower?
Once you’ve fed the new rope into the pulley, you can tie it with a simple overhand knot that’s pulled tight.
Some people use a lighter to “melt” the knot slightly to prevent it from coming undone.
