How to Fix Generator Pull Cord: A Step-by-Step Guide

A broken pull cord on your generator can be frustrating, especially when you need to use it urgently.

If you’re wondering how to fix generator pull cord, don’t worry—it’s a fixable issue. This guide will walk you through the process of repairing your pull cord, even if you’re not a seasoned handyman.

What is a Generator Pull Cord?

Before diving into how to fix a generator pull cord, let’s understand what it does. A pull cord, also known as a recoil starter, is a critical component that allows you to manually start your generator. By pulling the cord, you engage the engine, which kicks it into motion.

Why Does a Generator Pull Cord Break?

There are several reasons why your generator pull cord might break:

• Wear and Tear: Over time, the cord can fray and snap due to constant use.
• Poor Quality Cord: Low-quality cords are more likely to break prematurely.
• Improper Handling: Rough or forceful yanking can weaken the cord over time.

Now that you know the causes, let’s look at how to fix a generator pull cord step-by-step.

Tools Needed to Fix a Generator Pull Cord

Before you begin the repair process, gather the following tools:

• A new pull cord (ensure it’s compatible with your generator model)
• A screwdriver (flathead or Phillips, depending on your generator)
• A wrench (for loosening bolts)
• Pliers
• Needle-nose pliers
• Safety gloves

Step-by-Step Guide: How to Fix Generator Pull Cord

Step 1: Turn Off and Disconnect the Generator

Safety first! Before you start repairing your generator’s pull cord, ensure that the generator is turned off. Also, disconnect the spark plug to prevent accidental starting.

Step 2: Remove the Recoil Assembly

Locate the recoil assembly—this is where the pull cord is housed. It’s usually mounted on the side of the generator engine. Use a screwdriver to unscrew the bolts holding the cover in place. Be sure to keep the screws in a safe place, as you’ll need them to reassemble the generator.

Step 3: Remove the Broken Pull Cord

Once the recoil assembly is open, you’ll see the pulley and the remnants of the broken pull cord. Use pliers to carefully remove the broken cord from the pulley mechanism. Take note of how the cord was originally threaded, as you’ll need to replicate this when installing the new cord.

Step 4: Measure and Cut the New Cord

Cut a piece of the new pull cord that matches the length of the old one. Most pull cords range between 4 to 5 feet, but it’s always best to refer to your generator’s manual for the correct length.

Step 5: Thread the New Pull Cord

Here’s where precision matters! Feed the new pull cord through the recoil housing and into the hole in the pulley. Tie a secure knot at the end of the cord to ensure it stays in place. Using needle-nose pliers can help you thread the cord more easily.

Step 6: Rewind the Pulley

After you’ve inserted the new cord, you’ll need to rewind the pulley to create the tension needed for starting the generator. Turn the pulley in the same direction it normally spins when you pull the cord. Once tension is created, secure the cord to the handle.

Step 7: Reattach the Recoil Assembly

Now that your new pull cord is in place and the pulley is rewound, it’s time to put everything back together. Reattach the recoil assembly to the generator engine, tightening the screws with your screwdriver.

Step 8: Test the Pull Cord

Reconnect the spark plug and try pulling the cord to see if it works smoothly. If everything was reassembled correctly, your generator should start up with no issues.

Common Issues When Fixing Generator Pull Cords

Even though fixing a generator pull cord is straightforward, there are some common problems you might encounter:

Cord Won’t Retract

If the pull cord won’t retract after replacing it, the recoil spring may not be wound tightly enough. You’ll need to go back and increase the tension by winding the pulley a few more times.

Cord Snaps Again

If your new pull cord breaks soon after replacement, it could be due to low-quality materials. Ensure you’re using a durable cord that’s designed for your generator’s specific model.

Preventive Maintenance Tips for Generator Pull Cord

To avoid frequently fixing your generator pull cord, keep these maintenance tips in mind:

• Pull the cord gently: Avoid yanking it too forcefully, as this puts strain on both the cord and the pulley.
• Inspect regularly: Check for signs of fraying or damage to the cord during routine generator maintenance.
• Lubricate the pulley: A little lubricant can help the pulley mechanism move more smoothly and reduce wear on the cord.

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Conclusion

Learning how to fix generator pull cord can save you time and money, preventing unnecessary trips to a repair shop. The steps outlined above are easy to follow, even for beginners.

By keeping up with regular maintenance and using quality replacement parts, you can keep your generator’s pull cord functioning smoothly for years to come.