How do you fix a broken pull cord on a lawnmower?

A broken pull cord on a lawnmower can be very frustrating. The pull cord is the mechanism that starts the lawnmower when you give it a brisk tug. Without a functioning pull cord, you won’t be able to start your lawnmower to mow the lawn. But not to worry, with a few tools and some mechanical know-how, you can have your lawnmower up and running again in no time.

What causes a pull cord to break?

There are a few common reasons why a lawnmower pull cord might break:

• Normal wear and tear – The repeated pulling on the cord over time can cause it to deteriorate and eventually snap.
• User error – Pulling the cord too aggressively or at an awkward angle can overstress it and cause it to break.
• Damage – If the pull cord gets caught on something as you’re pulling it, the sudden jerk could break it.
• Old age – Over many years of use, the pull cord can become brittle and prone to breaking.

The pull cord is made of a braided nylon rope and is designed to withstand repeated and forceful pulling. But nothing lasts forever, and a worn out or damaged pull cord will eventually give out.

How to diagnose a broken pull cord

Before you can fix it, you’ll need to take a closer look to properly diagnose the problem. Here are some steps to help identify why your lawnmower’s pull cord isn’t working:

1. Check for visible damage – Examine the entire length of the pull cord and look for obvious signs of damage like fraying, kinking, or breakage. This can help pinpoint where and how the cord failed.
2. Try pulling it – Give the pull cord a few solid tugs and see if it still retracts as expected. If the cord pulls all the way out but doesn’t retract, the spring mechanism is likely broken.
3. Remove the housing – The pull cord on a lawnmower is housed in a removable plastic cover. Take this off to get a better look at the inner spring and pulley setup.
4. Inspect the recoil spring – Check if the recoil spring is still attached at both ends or if it has come unhooked from its housing. A detached spring will prevent the pull cord from retracting properly.
5. Test the pulley – The rope wraps around a pulley connected to the recoil spring. Spin the pulley by hand to see if the mechanism is still moving smoothly. If not, the pulley may be jammed.

By methodically going through these diagnostic steps, you should be able to identify exactly why your pull cord isn’t working and what parts may need to be replaced.

Tools and supplies needed

Before you get started on the repair, make sure you have the necessary tools and replacement parts on hand:

• Needle nose pliers
• Screwdriver
• Utility knife
• Replacement pull cord
• Replacement recoil spring (if needed)
• Replacement pulley (if needed)

The specific tools and parts required can vary depending on your lawnmower model. Check your owner’s manual for details on disassembling and reassembling your specific lawnmower.

After diagnosing the issue, inspect the pulley, spring, and housing to determine which parts need to be replaced. Then you can purchase replacement parts as needed.

How to remove the broken pull cord

Once you have the necessary supplies, you’re ready to get into the repair. Follow these steps to remove the broken pull cord from your lawnmower:

1. Disconnect the spark plug wire – This prevents the lawnmower from accidentally starting while you work on it.
2. Drain the gas – Tip the mower onto its side to drain the gas from the fuel tank and carburetor. Gas fumes can be dangerous, so work in a well-ventilated area.
3. Remove the housing – Use a screwdriver to take off the plastic housing that encloses the recoil mechanism and pull cord.
4. Cut away bad cord – Using utility scissors or a knife, cut off the section of pull cord that is frayed or broken.
5. Detach cord from handle – The handle end of the pull cord likely has a knot or other mechanism that attaches it. Carefully detach the cord from the handle.
6. Unwind cord – Grip the handle on the pulley and slowly let it unwind the remaining cord around it.

Once the old, broken pull cord is completely unwound and detached, the lawnmower recoil mechanism will be open and ready for the new cord to be installed.

How to replace the pull cord

Here are the steps to properly install a new pull cord on your lawnmower:

1. Thread new cord – Take the end of the new cord and feed it through the guide holes in the pulley. Wrap the cord evenly around the pulley, going in a clockwise direction.
2. Reattach spring – If the recoil spring came detached, reattach it to the pulley and housing per the manufacturer instructions.
3. Tie cord to handle – Leave 4-6 inches of cord at the end and tie a sturdy knot around the handle. You may need to pre-drill a hole in the handle to secure it.
4. Wind new cord – Crank the pulley clockwise several times. This will wind the new cord tightly around the pulley.
5. Reinstall housing – Carefully replace the plastic cord housing, making sure the spring aligns properly with the retainers.
6. Replace gas/spark plug – Refill the gas tank and reconnect the spark plug to finish the repair.

Give the new pull cord a few test pulls to make sure it retracts smoothly and has good tension. The lawnmower should now start up when you tug the cord. Be sure to check that the housing is securely reinstalled – this helps keep the recoil mechanism and pull cord properly aligned.

Troubleshooting tips

In some cases, the new pull cord may not work right away. Here are some troubleshooting tips for getting it working properly:

• Cord too loose – The cord may not be wound tightly enough around the pulley. Unwind it and rewrap it a bit tighter.
• Cord fraying – Fraying can happen if the pulley has rough spots. Use very light sandpaper to smooth it out.
• Spring detached – Check again that the recoil spring is seated in the retainers at both ends.
• Pulley jammed – Tap the pulley lightly with a hammer to free it up.
• Housing misaligned – If the cord housing doesn’t sit right, the spring can get pinched. Realign it until it sits flush.

With a little bit of troubleshooting and adjustment, you should be able to get the new pull cord operating correctly. Be patient and methodical to ensure proper installation.

When to take it to a repair shop

While a broken pull cord is usually a quick DIY fix, there are times when it may be best to take your lawnmower to a repair shop instead. Consider letting the professionals handle it if:

• The pulley or housing is cracked/broken – These require new replacement parts you may not have.
• The recoil spring is damaged – compact recoil springs can be tricky for amateurs to replace.
• There are other engine issues – A non-functioning pull cord could signal additional internal engine problems.
• You don’t have necessary tools – Without the right tools, the fix will be difficult.
• The repair is too complicated – If you’ve tried to replace the cord and are still stumped, let a professional take over.

A lawnmower technician will have the expertise, parts inventory, and tools to properly diagnose issues and fix it the right way. They can also identify if damage to the pulley, recoil, or other components is responsible for the broken cord.

Cost to repair a broken pull cord

If you do need to take your lawnmower to a repair shop, here are some average costs for fixing a broken pull cord:

Repair	Average Cost
Cord replacement only	$70 – $90
Cord + pulley/spring replacement	$110 – $150
Full recoil mechanism replacement	$150 – $200

Simple cord replacements are quickest, while recoil mechanism repairs take more time and labor. Additional engine work or parts can also add to the cost if needed.

Preventing future pull cord breaks

To help avoid needing pull cord repairs again in the future, here are some maintenance tips:

• Check the cord periodically – Look for signs of wear and replace if frayed or damaged.
• Avoid yanking too hard – Pull the cord slowly and steadily to reduce strain.
• Keep it clear of debris – Frequently clean grass clippings off cord to prevent damage.
• Let it retract fully – Don’t stop the cord mid-retract to prevent uneven winding.
• Store properly – Untwist cord and do not wrap tightly around handle when storing mower.

With proper care and handling, a quality pull cord should provide years of reliable starting. But even heavy-duty cords will eventually require replacement.

Conclusion

A broken pull cord is a common issue that can suddenly make your lawnmower useless. But with the right replacement cord, a few tools, and some DIY mechanical aptitude, you can usually get it fixed in an hour or less. For more complex recoil and pulley repairs, the help of a professional may be advisable. With routine maintenance and careful use, you can extend the life of your lawnmower’s pull cord and avoid unexpected starting failures while mowing the lawn.