Pull Cord Won’t Retract?
Uh, oh. It’s time to mow the lawn, but when you’re lawn mower cord is stuck! You give that cord a good hard pull, the cord doesn’t retract like it’s supposed to. Or worse, the mower fires up for a minute, and the cord is whipped back, you hear some funky grinding noise, and the mower dies. Subsequent pulls on the cord are futile because the cord won’t retract. Now what? Here’s how to fix it!
No problem! This is one of the most common problems I see with lawn mowers. It’s an easy fix.
The Starter Has Seized
The problem isn’t necessarily the cord; it’s the part on the top of the engine that is spun when the cord is pulled, called the starter clutch.
What’s happened is the starter clutch has rusted itself to the starting rod, making it impossible for it to lift, spin, or retract.
The Problem: Rusted Ball Bearings
The photo above shows where the problem lies. The ball bearings are rusted and the rust has affixed itself to the rod. Don’t worry, it’s not too difficult to fix on your own!
Follow the steps outlined below to have your mower up and running within an hour!
What supplies do I need? How much will they cost?
Fortunately, you don’t need many supplies; they’re likely already sitting around your garage!
Make sure you have fine-grade steel wool. It’s fairly inexpensive and can be purchased online or at any hardware store near you. For example, a 12-pack at Home Depot looks to be about $5 (As of 2022).
Once the bearings are cleaned, you also need oil or lubricant. Your mower’s user manual may tell you what kind is preferred for that model, or you can go with a more generic one. One made for small engines and outdoor equipment is recommended.
Step-by-Step Mower Repair
- Remove the starter cord from the pull handle.
- Remove three or four screws holding starter assembly on (instructions follow on recoiling the spring).
- Gently tap on the cap of the starter clutch.
- Remove starter clutch assembly.
- Using fine-grade steel wool, clean the rust off the ball bearings, clean out the bearing pocket, the shaft and any other rust you may come across.
- Before reassembling, you will probably need to recoil the starting spring.
- Reassemble, taking care to put several drops of oil in the center of the starter clutch (see additional instructions below).
To Oil the Bearings or Not?
I have heard that the bearings should be placed back in the clutch with no oil, instead using grease. I have found oil works best. Grease doesn’t last as long (in contact) with the bearings. I have also heard that the bearings and their housing should be oiled in addition to the centerpiece that needs oil.
I lean towards oil the bearings. Especially when the bearings are as rusted as the ones in the photo. I put them in an oil bath first, then drain off some of the oil and put several drops in the centerpiece. This method has worked for me for many, many years.
How to Recoil the Spring
After the rust is cleaned out and the ball bearings are put back in place, it’s time to fix the spring if it is sprung. Often, the spring is sprung from the starter seizing up. They’re not too difficult to recoil.
- Bend the tabs up so the coil can be removed from the housing.
- With the coil in hand, pull the end until the coil is compact and even; a nice spool.
- Now place the end holding tab into the housing and lay the rest of the coil in the housing carefully.
- Hang onto the coil so it won’t uncoil before you’re ready.
- While holding the spring with a small finger, place the coil on top of the spring inside the housing and carefully release the spring. The clutch will hold it in place while you bend the tabs down.
- Place the starter assembly back onto the clutch and put the screws back in.
- Guide the string back through the pull start hole in the housing and tie it back onto the handle.
Now you’re ready to fire it up!
Preventing Your Pull Cord From Getting Stuck
Of course, it’s best to try to prevent your pull cord from getting stuck in the first place. I suggest that you keep your mower in a dry place to prevent rust from developing. It also helps to clean the ball bearings and keep them lubricated regularly. Once you gauge how often the pull cord gets stuck, it will help you determine how often you should check to make sure it’s clean.
Safety Tips
Though this shouldn’t be a very long or dangerous process, there are a few things you should do to ensure your safety. It’s probably best to use gloves and be in a well-ventilated area when cleaning off the rust and applying the oil. Consider whether children or pets have access to the vicinity where you are doing the work. Once finished, make sure all products are cleaned up.
Make sure the lawn mower’s park plugs are disconnected as well. Though you’re struggling to start the mower, you don’t want anything to be triggered while working on it.