Pull Cord Replacement | Lawn Mower Starter Rope Fix

A broken pull cord stops your mower cold. The good news? This is a cheap fix you can do yourself in 30 minutes. This guide covers pull cord replacement on all major mower brands.

Table of Contents

• Symptoms of a Bad Pull Cord
• Tools and Parts
• Replacement by Brand
• Step-by-Step Replacement
• Recoil Spring Replacement
• Troubleshooting

Symptoms of a Bad Pull Cord

Cord won’t retract - The recoil spring is broken or unhooked. You pull the cord and it stays out.

Cord broke completely - The rope snapped. Usually happens at the handle or where it attaches to the pulley.

Cord pulls but engine doesn’t turn - The pawls (engagement fingers) are broken or the pulley is stripped.

Hard to pull - Could be a tangled cord, debris in the housing or engine problems (not the cord itself).

[NEED REAL IMAGE: Broken lawn mower pull cord]

Tools and Parts

Tools Needed

• Socket set (usually 8mm, 10mm or 3/8”)
• Screwdrivers (flathead and Phillips)
• Needle-nose pliers
• Wire cutters or scissors
• Lighter or matches (to melt rope ends)
• Zip tie or tape (to secure spring)

Replacement Parts

Starter rope - Standard sizes:

• #4 (1/8” or 3mm) - Most push mowers
• #5 (5/32” or 4mm) - Larger engines
• #6 (3/16” or 5mm) - Riding mowers

Rope length:

• Push mowers: 54-60 inches
• Riding mowers: 72-88 inches

Recoil spring - Only needed if spring is broken. Brand-specific.

Complete recoil assembly - Sometimes easier than rebuilding. $15-40 depending on brand.

Part Numbers by Brand

Brand	Rope Kit	Complete Assembly
Briggs & Stratton	695723	499706
Toro	105-1845	81-2310
Honda	28400-ZM0-003	28400-ZE1-003
Craftsman/MTD	753-08319	951-11196
Troy-Bilt	753-08319	951-11196
Kohler	24-150-14-S	24-150-04-S

Replacement by Brand

Toro Pull Cord Replacement

Toro Recycler mowers use Briggs & Stratton engines with a standard recoil design.

Specific steps:

1. Remove the three or four screws holding the engine shroud
2. Lift shroud to access recoil starter
3. Remove three bolts holding the recoil to the engine
4. Replace rope or entire assembly
5. Reassemble in reverse order

Toro part numbers:

• Rope only: 105-1845
• Complete recoil: 81-2310 (Recycler 22)

[NEED REAL IMAGE: Toro Recycler recoil starter removal]

Craftsman Pull Cord Replacement

Craftsman mowers (M110, M220, M230 etc.) use similar Briggs engines.

Specific steps:

1. Remove air filter cover and filter
2. Remove engine shroud bolts (usually four)
3. Lift shroud - recoil is attached
4. Remove three recoil mounting bolts
5. Replace rope or assembly

Craftsman part numbers:

• Rope kit: 753-08319
• Complete recoil: 951-11196

Troy-Bilt Pull Cord Replacement

Troy-Bilt TB110, TB200, TB230 and other models follow the same procedure as Craftsman (both are MTD products).

Key differences:

• Some models have the recoil integrated into the shroud
• TB30R riding mower has a side-mounted recoil

Troy-Bilt part numbers:

• Rope: 753-08319
• TB110/TB130 recoil: 951-11196
• TB230 recoil: 951-12102

[NEED REAL IMAGE: Troy-Bilt TB110 recoil starter]

Honda Pull Cord Replacement

Honda GCV160 and GCV190 engines have a different recoil design with a ratcheting mechanism.

Specific steps:

1. Remove three screws from the fan cover
2. The recoil is now accessible
3. Remove three bolts holding recoil to engine
4. Replace rope or assembly
5. When reinstalling, align the pulley notch with the engine

Honda part numbers:

• GCV160 rope: 28400-ZM0-003
• GCV160 recoil: 28400-ZE1-003
• GCV190 recoil: 28400-Z8B-003

Honda tip: The friction plate inside the recoil needs proper alignment. If the cord won’t engage the engine, rotate the pulley to align the ratchet mechanism.

Briggs & Stratton Pull Cord Replacement

Most Briggs engines 450-850 series use the same basic recoil design.

Variations:

• Older engines have metal pulleys
• Newer engines have plastic pulleys
• Some have an integrated rope handle

Briggs part numbers:

• Universal rope kit: 695723
• 450-550 series recoil: 499706
• 625-850 series recoil: 591139

[NEED REAL IMAGE: Briggs & Stratton recoil starter disassembled]

Step-by-Step Replacement

This general procedure works for most push mowers. Adjust based on your specific model.

Removing the Old Cord

Step 1: Access the Recoil

Remove the engine shroud to expose the recoil starter. This usually requires removing 3-5 screws or bolts.

Step 2: Remove the Recoil Assembly

Unbolt the recoil from the engine (usually three bolts). Set it on your workbench.

Step 3: Remove the Center Bolt

A single bolt or screw holds the pulley in place. Remove it carefully - the spring is under tension.

Warning: The recoil spring can unwind violently. Wear safety glasses and keep fingers clear.

Step 4: Remove the Pulley

Lift the pulley out. Note how the rope is wound and where it attaches.

Step 5: Remove the Old Rope

Untie or cut the knot at the pulley and pull the old rope out through the housing.

Installing New Rope

Step 1: Prepare the New Rope

Cut rope to length (typically 54-60 inches for push mowers). Melt both ends with a lighter to prevent fraying.

Step 2: Thread Through Housing

Push the rope through the hole in the recoil housing from the outside.

Step 3: Tie to Pulley

Thread the rope through the pulley hole and tie a secure knot. A figure-8 knot works well. Pull tight.

[NEED REAL IMAGE: Pull cord knot on recoil pulley]

Step 4: Wind the Rope

Wind the rope around the pulley in the correct direction (usually counterclockwise when viewed from above). The spring determines which way.

Step 5: Pre-tension the Spring

Before installing the pulley:

1. Wind the pulley to pre-load the spring
2. Count the turns - typically 4-6 depending on the model
3. Hold tension while seating the pulley

Step 6: Align and Install Pulley

Set the pulley in place, aligning any tabs or notches. Install the center bolt.

Step 7: Test Retraction

Pull the cord out slowly and release. It should retract smoothly. If not, add or remove pre-tension.

Step 8: Attach Handle

Thread the rope through the handle. Tie a stopper knot inside the handle.

Step 9: Reinstall on Engine

Bolt the recoil back onto the engine. Replace the shroud.

Recoil Spring Replacement

If the spring is broken, you’ll need to replace it. This is trickier than just replacing the rope.

Signs of Broken Spring

• Cord pulls out but won’t retract at all
• Spring visibly broken or unwound
• Pulley spins freely without resistance

Spring Replacement Steps

Step 1: Remove Old Spring

With the pulley removed, carefully lift out the old spring. It’s usually wound in a spiral inside the housing.

Step 2: Install New Spring

New springs come pre-wound. Keep them contained until installed.

1. Place the outer end of the spring in the housing notch
2. Press the spring coil into the housing
3. The inner end hooks onto the pulley

Step 3: Wind and Test

Install the pulley, wind rope and test. The spring should provide smooth retraction.

[NEED REAL IMAGE: Recoil spring installation]

Pro tip: If the spring escapes and unwinds, use needle-nose pliers to carefully wind it back into a coil. Secure with a zip tie until you can reinstall it.

Troubleshooting

Cord Retracts Slowly

• Spring weak or tired - replace spring
• Cord binding on housing - check for debris
• Wrong rope size - too thick causes friction

Cord Won’t Engage Engine

• Pawls broken or stuck - clean or replace
• Pulley stripped - replace pulley
• Flywheel cup damaged - less common but possible

Cord Hard to Pull

• Engine problem - not the recoil
• Debris in housing - clean thoroughly
• Wrong size rope - too thick

Cord Keeps Breaking

• Sharp edge on housing - file smooth
• Knot slipping - use better knot
• Wrong rope type - use braided nylon

Handle Keeps Coming Off

• Better stopper knot needed
• Handle cracked - replace handle
• Consider zip tie backup inside handle

When to Replace the Whole Assembly

Sometimes replacing just the rope isn’t worth it:

• Spring broken and replacement spring costs $10+
• Housing cracked
• Pawls worn or broken
• Multiple components failing
• Time is more valuable than parts cost

Complete recoil assemblies run $15-40. They come ready to install with new rope and spring. Often the easiest fix.

Related Guides

• Lawn Mower Won’t Start
• Toro Recycler Repair Guide
• Craftsman M220 Problems
• Troy-Bilt Mower Problems
• Small Engine Maintenance

Summary

Pull cord replacement is straightforward once you’ve done it. Remove the shroud, unbolt the recoil and swap the rope. The hardest part is managing the spring tension. If that seems daunting, buy a complete recoil assembly and bolt it on. Either way, you’ll be mowing again in under an hour.