Repair Lawn Mower Pull Cord

March 15, 2011

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Lawn Mower Engine Starter Assembly

Lawn Mower Engine Starter Assembly

Lawn mower starts when the user pulls the cord, wrapped around a pulley, that is located inside the lawn mower engine. The pulley spins once the cord is pulled and this spin allows the engine to start.

Even though it is made out of heavy-duty nylon rope, the pull cord frays and weakens over a period time. When the pull cord weakens, the rope will eventually snap, and for the lawn mower engine to start, the cord will have to be replaced.

You can take the easy way out and change the entire lawn mower starter assembly.

To change just the cord itself, here are step by step instructions:

  • Before you do anything, disconnect the spark plug wire.
  • Using a screwdriver, remove the screws holding the engine cover.
  • If the removal of the cover does not seem obvious to you, read the lawn mower instruction manual to find out the correct way to remove it.
  • Remove the starter pulley from the engine.
  • From around the pulley, unwind the old pull cord.
  • Measure the new cord to a length of about ten inches, then use the scissors to cut it.
  • In the side hole of the starter pulley, push one end of the newly cut cord.
  • To make sure that the rope does not pull straight through, tie a knot at the end of the rope.
  • Without spinning the pulley, wrap the cord around the pulley two times.
  • In the side of the pulley cover, thread the loose end of the cord.
  • Place the pulley and the cover back on the engine, then secure them with screws or bolts again.
  • To make sure the pulley spins freely, and rewinds the cord without tangling and rumpling, give it a few tugs.
  • Remove the handle from the old chord, and pull the new cord through the holding circle on the side of the handlebar.
  • Attach the pull handle to the new cord.
  • Position the handle on the cord so that it will not hang loosely.
  • Cut the excess cord off
  • Reconnect the spark plug wire.

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