If your Craftsman lawn mower’s pull cord has snapped, frayed, or stopped retracting, you can replace it yourself in about 30 minutes with basic hand tools. The process involves disconnecting the spark plug, removing the starter housing, installing a new cord through the recoil pulley, rewinding the spring, and reassembling everything. This guide walks you through each step for both push and riding Craftsman mowers, with safety warnings and troubleshooting tips to get your mower running again.
Before You Start: Safety and Tools
Replacing the pull cord on a Craftsman lawn mower is a straightforward DIY task, but safety should come first. The most important step is to disconnect the spark plug wire before touching anything near the engine. This prevents the engine from accidentally starting while you work on the starter assembly, which could cause serious injury. Simply pull the rubber boot off the spark plug and tuck it away from the plug so it cannot make contact.
You will need a few basic tools for this job. A Phillips or flathead screwdriver is typically required to remove the starter housing bolts. A socket set with extensions may be necessary for riding mowers where the starter is mounted under the hood or in a tight space. Needle-nose pliers help with pulling knots through small holes, and a small flathead screwdriver is useful for prying out stubborn parts. You will also need a replacement pull cord.
For most Craftsman walk-behind push mowers, the replacement cord is typically 3/32-inch or 1/8-inch in diameter and about 5 to 6 feet long. Riding mowers may use a slightly thicker cord. You can purchase pre-cut starter rope at hardware stores or online, or buy a bulk roll and cut it to length yourself. If you are unsure about the exact size, take the old cord with you to the store to match it. Avoid using ordinary household rope, as it may not be durable enough or have the right diameter to fit through the pulley hole.
Removing the Starter Housing
On a Craftsman push mower, the starter housing is the round plastic or metal cover located on top of the engine, directly above the fuel tank. It is usually held in place by two or three bolts or screws. Use the appropriate screwdriver or socket to remove these fasteners and set them aside in a safe place so you do not lose them. Once the bolts are removed, gently lift the housing off the engine. Be careful, as the recoil spring inside is under tension and may try to unwind.
For Craftsman riding mowers, the procedure is similar but the starter housing may be located under the hood or on the side of the engine. You may need to remove a larger cover or access panel to reach it. On some models, the starter is mounted vertically or horizontally, and the housing may be secured with bolts that require a socket wrench. If the housing is difficult to reach, consider removing the hood or other obstructing parts first. Always consult your owner’s manual for model-specific instructions if available.
If the housing bolts are stuck or rusted, apply a penetrating oil like WD-40 and let it sit for a few minutes before attempting to loosen them. Use a properly fitting screwdriver or socket to avoid stripping the heads. If a bolt is severely rusted, you may need to use a bolt extractor or carefully drill it out, but this is uncommon. Patience and the right tool will usually free a stuck bolt without damaging the housing.
Removing the Old Pull Cord
With the starter housing removed, you will see the recoil starter assembly. This consists of a pulley, a recoil spring, and the cord itself. Before removing the old cord, you need to release the tension on the recoil spring. On most Craftsman mowers, the spring is pre-tensioned. To release it, locate the small notch or tab on the pulley where the cord is anchored. You may need to hold the pulley firmly while you untie the knot or pull the cord out through the guide hole.
If the cord is broken inside the housing, you will need to remove the pulley to access the remnants. On many models, the pulley is held in place by a center screw or a retaining clip. Remove this fastener and lift the pulley out carefully. The recoil spring may be housed in a separate compartment or attached to the pulley. Take note of how the spring is oriented before removing anything, as you will need to reassemble it correctly.
To untie the knot from the pulley, use needle-nose pliers to pull the cord through the pulley hole and expose the knot. Cut the knot off with scissors or a knife, then pull the cord out through the guide hole in the housing. If the cord is stuck or frayed, you may need to push it out from the inside. Once the old cord is removed, clean any debris or grass clippings from the pulley and housing before installing the new cord.
Installing the New Pull Cord
Thread the new cord through the guide hole in the starter housing, leaving a few inches of slack on the inside. Then, feed the end of the cord through the hole in the pulley. The pulley typically has a small hole near the center where the cord is anchored. Pull the cord through until you have about an inch of slack on the other side.
Tie a secure knot at the end of the cord. A simple overhand knot or a figure-eight knot works well. Make sure the knot is large enough that it cannot pull back through the pulley hole. Some users prefer to melt the end of the cord slightly with a lighter to prevent fraying, but this is optional. Pull the cord taut to seat the knot firmly against the pulley.
Now you need to wind the cord around the pulley. The number of wraps depends on the length of the cord and the diameter of the pulley, but typically you will wind it 3 to 4 times. Start by pulling the cord through the pulley hole until the knot is seated, then wind the cord around the pulley in the direction that matches the spring’s winding direction. On most Craftsman mowers, this is counterclockwise when viewed from the top. Leave enough cord outside the housing to reach the handle and allow for a comfortable pull.
Rewinding the Recoil Spring
After the new cord is installed and wound around the pulley, you need to re-tension the recoil spring. This is the step that gives the starter its retraction force. If the spring is not wound properly, the cord will not retract or may pull too hard. To rewind the spring, turn the pulley in the direction that tightens it. On most Craftsman mowers, this means turning the pulley counterclockwise. You will feel resistance as the spring tightens.
Turn the pulley until the spring is snug but not overly tight. A good rule of thumb is to wind it until you feel firm resistance, then back off slightly. If you wind it too tight, the cord will be hard to pull and the spring may snap. If you wind it too loose, the cord will not retract fully. The exact number of turns varies by model, but typically 3 to 5 full rotations is sufficient. Some starters have a small mark or indicator that shows the correct tension, so check for that if present.
If the recoil spring is broken or worn out, you will need to replace it. Symptoms of a broken spring include a cord that does not retract at all, a grinding noise when pulling, or a starter that feels loose and floppy. Replacement recoil springs are available for most Craftsman models and are relatively inexpensive. Installing a new spring is similar to rewinding the old one, but you must ensure the spring is seated correctly in its housing before winding.
Reassembling and Testing
Once the new cord is installed and the spring is tensioned, you can reassemble the starter housing. Feed the cord through the guide hole in the housing if you have not already done so, and pull the handle to the end of the cord. Then, align the housing with the mounting holes on the engine and press it down gently. Make sure the pulley and spring are seated correctly before securing the housing with the bolts or screws you removed earlier.
Tighten the bolts evenly, but do not overtighten them, as this can strip the threads or crack the housing. Once the housing is secure, test the pull cord by giving it a gentle tug. The cord should extend smoothly and retract back into the housing when you release it. If the cord does not retract, the spring may be too loose or not seated correctly. If it pulls too hard, the spring may be over-tensioned.
After testing the starter, reconnect the spark plug wire. Start the mower to confirm everything works correctly. If the cord pulls smoothly and the engine starts, you have successfully replaced the pull cord. If you notice any issues, such as the cord sticking or the starter making unusual noises, double-check your work and adjust the spring tension as needed.
Troubleshooting Common Issues
If your new pull cord is stuck or hard to pull, the most likely cause is over-tensioned recoil spring. Remove the housing and unwind the spring slightly by turning the pulley clockwise. Conversely, if the cord does not retract, the spring may be too loose or may have come off its anchor point. Check that the spring is seated correctly and rewind it with more tension.
If the cord retracts but the engine does not start, the problem is likely not the cord itself. Check the spark plug, fuel supply, and air filter. The starter may also be slipping if the pawls or other internal components are worn. If the cord pulls freely but does not engage the engine, the starter assembly may need to be replaced entirely.
You should consider replacing the entire recoil starter assembly instead of just the cord if the spring is broken, the pulley is cracked, or the housing is damaged. These parts are often sold as a complete unit and are relatively easy to install. If you have attempted to repair the starter multiple times and it continues to fail, a full replacement is usually more cost-effective and reliable.
Frequently Asked Questions
Can I use any type of rope as a replacement pull cord? No. You should use a cord specifically designed for recoil starters. These cords are made from durable nylon or polypropylene and have the correct diameter to fit through the pulley hole. Ordinary rope may fray, stretch, or break quickly.
How often should I replace the pull cord on my Craftsman mower? The pull cord typically lasts several years with normal use. However, if you notice fraying, cracking, or difficulty pulling, it is best to replace it before it breaks. Inspect the cord periodically, especially before the mowing season.
Is it worth repairing the recoil starter or should I buy a new one? If only the cord is worn, repairing it is inexpensive and worthwhile. If the spring or pulley is broken, you can still repair it with replacement parts. However, if the housing is cracked or the starter has multiple issues, buying a complete replacement starter assembly is often simpler and more reliable.
